USYS 2100Monitoring, Data Control, Acquisition and Display

for Single and Multi Sensor Applications.

New user friendly design Operator interface with choice of languages

New menu driven, context sensitive software keys

New faster and more efficient software platform

Status of your line at a glance

Intelligent SIGMA EXPERT control and Cpk pilot

Rugged and reliable combination of proven and innovative technology

Bright high resolution color TFT LCD screen

Unlimited number of product recipes

Strip chart, SPC data and graphics

Reel Report, Session Report, Data Log

CE compliant

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Diameter and Thickness Control

USYS 2100 – The Universal Processor, Operators Will Love

Recipe Memory

Multifunctional Can Be Used With Any Zumbach Gauge

Typical sensors which can be connected to the USYS 2100 processor:

Communication and Networking

The operator friendly USYS 2100 is an updated version of the USYS 2000 which has been proven in numerous applications. Its flexible configuration, with CPU, I/O PCBs and process-specific intelligence from the extensive Zumbach software library, provides optimal adaptability to suit the process and production line. A complete status display of the parameters informs continuously on the performance of the production line. This makes the USYS 2100 an ideal solution for diameter, wall thickness, capacitance, concentricity/eccentricity and fault control.

Up to 2 sensors may be connected for dimensions. It is also possible to connect KW fault detectors, spark testers and a length detector. All faults can be logged and identified.

Every USYS 2100 includes 1 SIGMA EXPERT controller with Static Regulating Device (SRD) or relay output. The SIGMA EXPERT controller is self-optimizing. It does not require further parameter optimization and even provide dynamic regulation of the process during start-up.

Unlimited product recipes can be stored in the memory and are constantly accessable. Any amount of products can be managed by an external PC connected to the serial or the Ethernet interface. The statistics for the quality of every reel as well as of the entire production are calculated by USYS and are available to the host computer.

USYS 2100 manages and monitors quality and production costs by simultaneously carrying out all the following functions (multitasking):1. Continuous measurement and display 2. Monitoring of the limit values 3. Diameter, wall thickness, concentricity/ eccentricity, capacitance control 4. Material savings 5. Recipe management 6. Statistics and data logging, SPC control charts 7. Communication with a computer

ZUMBACH offers a variety of interface units and USYS software to satisfy almost any need to communicate with other computers or networks.

USYS Web ServerThis optional software enables the display of information from USYS processor at remote terminals. Whilst the USYS processor is working it is also possible to edit the product table from one or several terminals. Communicates via LAN. Viewing with Internet Explorer or other browser.

USYS Data LogWindows™ based software for easy data collection from one or several processors and for saving the data in text or Excel™ files.™ Windows and Excel are trademarks of Microsoft Corporation

ApplicationsDifferent configurations are possible, depending on the user's needs and requirements:•CentralizingtheInformation•DistributingtheInformation•ManagingtheUSYSprocessorfromdifferent remote locations•MultiTerminal/MultiUserSystem

Production manager

Quality control

Production planning

Forwarddepartement

USYS 8100

USYS 2100and/or

ODAC® for diameter

ODEX® 10 for concentricity/eccentricity and diameter

CAPAC®

for capacitanceKW for lump

and neckdownSpark Tester for cable insulations

LANIntranet

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A Selection of Typical Application Configurations:

USYS 2100 – In the Wire, Cable, Plastics, Rubber and Other Industries

Diameter and Eccentricity Measurement, Spark Tester and Lump Detector/NeckdownFull cold end product information with automatic control of diameter through capstan speed or extruder screw rpm.

USYS 2100 – In the Steel and Metal IndustryUSYS 2100 is available with dedicated software for products such as rods, bars, sleeves, tubes, profiles, bolts and others in milling and forming processes. The special software features a selectable end suppression for the start and end of a product, so that end deformations do not figure in the statistical data and do not cause unintended corrective action. Alarms and pre-alarm limits can be set to control the production process and to warn the operator before product tolerance limits are reached. User friendly screens allow process status recognition "at a glance". Trend information is also shown which immediately informs the operator about the product variability. The menu driven software allows the user to specify the parameters for statistical evaluation and the statistical acquisition periods as required.

Hot and Cold Diameter & Eccentricity, Spark Tester and Lump Detector/NeckdownFor quick control based on the hot end diameter measurement taking into account the shrinkage as the product cools.

Capacitance or Diameter Control & Eccentricity, Spark Tester and Lump Detector/NeckdownSelect capacitance or diameter as the most important parameter to control, depending on the product specification.

Typical Processes Typical Display Configurations

PeelingThe instruments are arranged according to customer request or at the end of the production line for measurement of the finished product.

Cold RollingWire or profiles are rolled to a final, more precise tolerance. ODAC®

diameter gauges measure the final product.

QC Stations (Non-destructive testing)In-line measurement at QC stations integrated into the production line or at the end. A typical check of outside dimensions is achieved with ODAC® measuring heads.

GrindingCenterless grinding as well as grinding between centers for in-process and post-process applications.

PolishingODAC® diameter gauges, mostly single axis, measure the bright finished bar.

Cold DrawingIn-line measurement allows the user to monitor die wear, die breaks, scratches or any other defects or diameter variations.

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SIGMA EXPERT Controller and Cpk Pilot HOT/COLD Control (Dual Loop)Intelligent and self-adjusting systems for dynamic control even during start-up. By means of the Cpk Pilot, the nominal value is automatically adjusted to the lower limit given by statistical computations.

This means important material savings!

Patents: GB 2 145 852 B and others

As a result of using 2 measuring gauges and a SIGMA EXPERT controller, dynamically optimal control is obtained with respect to the cold value.

Application Limits1 or 2 ODAC® Dimensional sensors or 1 or 2 CAPAC® Capacitance sensors, 1 ODEX® Concentricity/eccentricity and diameter gauge, 2 Event inputs (KW, Spark Tester), 1 Controlled Parameter.

Typical Screens

Capacitance value (With CAPAC® measuring system)

Bar rolling: Mean diameter information (With 2 ODAC® gauges)

Statistics, showing full graphical SPC pages: Histogram or X-Bar/Range

Bar rolling: Mean diameter, statistics summary, characteristic strip chart information etc.

Concentricity display (With ODEX® measuring system)

Diameter and eccentricity information(With ODAC®

and ODEX® measuring units)

Material savings

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USYS 2100 Front Panel Features

Example of Main Screen Extrusion line with 2 diameter gauges, 1 eccenctricity and diameter measuring system, 1 fault detector and 1 spark tester

Select the number on the numeric keypad or navigate with the cursor keys to display information specific to the device identified on the line layout.

"Trend charting" of controlled parameter

Depiction of the line layout (user configurable)

Direct access key labels

Value of parameter being monitored/controlled

Power on/off switch

Alphanumeric keyboard connector (PS/2 connector)

Numeric keypad

8.4" TFT LCD color screenwith antireflective protection glass

Navigation and cursor keypads

Direct access function keys

Display Software

Mode keySwitch between operator mode and configuration mode

Navigate with the cursor to view the Max, Min, Average etc. of controlled parameter

Relevant parameter status and value displayed in these windows

System information key

Context specific function keys

USB port

TFT LCD display. Modern graphic user interface – context sensitive software keys, direct access function keys and menu.•Lineandsystemconfiguration•Measuredvalues•Statusofmeasuredvalues(inoroutoftolerance)•Alarms•Errormessages•Stripchart,trendanalysis•SPCdataandgraphics•Producttableforunlimitedproductrecipes

•"RealTime"multitaskingoperatingsystem•2Functionmodes: –Operatormode – Configuration mode•5contextsensitivesoftwarefunctionkeys•Systemsecurityincaseofmainspowerfailure•Simplesoftwareupdateswithflashdisk or USB memory stick

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USYS 2100 Rear Panel Features

Measuring head connector(s)Amphenol connectors for the connection of any digital ODAC® J or CAPAC® J-type sensor.

SpecificationsBasic configurationIndustrial PC (1 Ethernet, 3 USB 1.x, 2 RS-232, 1 Centronics, 8.4" TFT LCD, 32 MB flash disk). 1 CP.311 for one ODAC® sensor, 1 IO.012 for input/output, controller, alarm, 1 SRD (Static Regulating Device).

Dimensions

Dimensions in mm (in.)

1) without case 2) 1 HU = Height Unit = 44.45 mm (1.75 in.)

•Technicalspecificationsaresubjecttochangewithoutnotice

USY

S.0

04

.50

06

.E M

AY.

20

08

Power90 ... 135 / 180 ... 265 VAC (auto-select), 47 ... 63 Hz

Operating temperature0 ... 50° C (32 ... 120° F)

WeightApprox. 17.2 kg (38 lbs.)

USB ports

2 Motorola I/O channel slotssupporting an array of input/output PCBs needed to interface the system to the "outside world".Alarm/analog outputs expansion features tolerance pre-alarm and SPC trend alarm

Connector forparallel screen

System printer(desktop or rack mount)– data logging with length and time data– reel end and session end reports

Centronics LPT 1

RS-232 COM 1, COM 2 Label / tag printerreel end summary printed onto self-adhesive labels or tags (contents configurable by user).

Host computer / PLCup/download

"SRD" Static Regulating Device (or motorized potentiometer).Control of line speed/extruder screw r.p.m.

MPK1-10TMotorized potentiometer with servo valve for control of internal air support pressure.

Line speed/footage counter inputProximity detector/WG2-/TI 069

or

ISA Bus slots for system expansion

Connector for external keyboard

Chart recorder analog

Event inputs (lumps, neckdowns, spark failures etc.)

Switzerland: Zumbach Electronic AG, P. O. Box, CH-2552 Orpund, Phone +41 (0)32 356 04 00, Fax +41 (0)32 356 04 30, E-mail: sales@zumbach.chUSA: Zumbach Electronics Corp., 140 Kisco Avenue, Mount Kisco, NY 10549-1407, Phone +1 914 241 7080, Fax +1 914 241 7096, E-mail: sales@zumbach.com

Other ZUMBACH companies in Argentina, Belgium, Brazil, China, France, Germany, India, Italy, Spain, Taiwan and UK plus agents and service in more than 40 countries.

www.zumbach.com

Mains connectorIntegrated connector with mains filter.

Ethernet

Ground connectionMouse PS/2

USYS 2100 meets the current CE standards regarding overall performance and EMC (Electro Magnetic Compatibility).

Multi-port PCB RS-422– Included at "E" software versions (ODEX) – Option for "A" software versions

510 (20.1)

21

0 (

8.2

3)

500 (19.7)

403 (15.8) 1)

483 (19.0) 1)

17

7 (

7) 1

)

4 H

U 2

)

Description N6.IO.003 N6.IO.005 N6.IO.011 N6.IO.012

Digital inputs 8 5 8 7

Analog inputs – – 4 –

Digital outputs – 4 – 5

Analog outputs – 1 4 2

Relay outputs 8 5 – 3

Inputs / OutputsThe use of one additional board allows many different combinations. According the type, number and combination, the number of inputs and outputs change.

Type of boards