Prime DS101 Bedienungsanleitung

OPERATING INSTRUCTIONS

Model DS101 DOUBLE SHEET DETECTOR

DESCRIPTION

The Model DS101 Double Metal Sheet Detector comprises a control module in a polycarbonate

housing with a single probe to form a system that detects the thickness of ferrous (magnetically

attracted) metals passing the face of the probe. The detector system may be used on automatic

sheet feeders where double or overlapped sheet material may jam or damage the receiving

machine. A double feed produces an output to stop the machine or signal the operator.

March 12, 1999

1 2

N.C.

WIPER

N.O.

NOTHING

COM

RESET

CAL

RED

WHITE

BLACK

SHLD

PRIME

CONTROLS, INC.

Model DS101

Double Metal

Detector

CALIBRATE

FUSE

NO DOUBLE DOUBLE

Control Module

The control module allows fast and easy setup and for diagnosis of system errors or problems.

Calibration is achieved through the simple press of a push-button switch. Faults are reported

through different flash patterns on the green and yellow "no double" and "double" indicators.

When the unit first powers up, the two indicators flash alternately as the unit determines which

model of probe is attached. If the probe is not recognized, the flash pattern changes with the

DOUBLE indicator on solid and the NO DOUBLE indicator flashing. When probe assessment

has completed successfully, the indicators stop flashing

Other features of the control module include:

•95 to 130 or 200 to 250 volt operation selected through internal jumpers.

•Form C relay output providing normally open or normally closed contacts.

•LED indicators report the gauge states of NO DOUBLE and DOUBLE.

•Automatic setup of system gain and operating parameters.

•Simple push-button calibration.

•Non-volatile memory that retains all calibration parameters even when power is removed.

•Latching relay output that is cleared by asserting the RESET input.

•Probe fault detection and reporting via the two front panel indicators.

•External Calibrate terminals for convenient placement of the calibrate switch

•Metal present output to verify the sheet has fed properly

Probes

The DS101 operates with a several different Prime magnetic probes including Models PM4,

PM10, and PM15. All probes are potted and completely sealed. The probes do not respond to

small amounts of fine metal filings, oil or dirt.

Probe Model Min thickness Max thickness Probe Diameter

PM4 .04 mm (.0015”) .40 mm (.015”) 18 mm (0.70”)

PM10 .10 mm (.004”) 1.0 mm (.040”) 30 mm (1.18”)

PM15 .15 mm (.006”) 1.5 mm (.060”) 36 mm (1.42”)

INSTALLATION

Installation of the individual components of the Double Metal Sheet Detector system is covered

in the following paragraphs:

DS101 Control Module

The control module is designed to be mounted either in the open on a machine member or on the

back panel of an electrical enclosure using the four mounting holes at the corners of the

enclosure. The footprint is 4.75 inches (120 mm) wide by 6.70 inches (170 mm) high with

mounting hole locations on a rectangle 3.575 inches (91 mm) in the horizontal and 6.25 inches

(159 mm) in the vertical (see drawing at end of this document). Avoid mounting locations with

excessive heat and vibration.

Probes

The probe must be mounted so that the sheet is in contact with the probe face as it passes. The

face of the probe is made of magnetic material and will last for many years of operation.

The Model DS101 Double Sheet Detector can be made to operate with no contact between the

sheet material and the probe if the gap is kept very small and is held constant. A constant gap is

very important since a small change in gap causes significant change in the sensor signal. If the

system is to be operated with a gap between the probe and the sheet material, the unit must be

calibrated after the gap is established. If the gap is too large, the unit may fail to calibrate and will

indicate the failure through simultaneous flashing of the yellow and green indicators.

Electrical Wiring

All wiring for the DS101 connects to terminal blocks at the bottom of the control circuit board

within the enclosure as described in the following paragraphs.

1. Connect l00 to l30 VAC (50-6O Hz. @15watts) to the terminals labeled AC on the left of

terminal block. Connect earth ground to the terminal marked with the ground symbol.

2. Do not power the Model DS101 with 200 to 260 VAC until jumpers have been changed.

For 200 to 260 volt operation remove the DS101 front panel (four screws) and remove

suitcase jumpers Aand Cimmediately in front of the gray transformer block. Place one of

the suitcase jumpers in position B. Discard the second jumper. Replace the front panel.

The factory setting for these jumpers is for 100 to 130 volt operation.

3. Connections to the control circuit of the machine are made through the form C output relay.

This relay is powered in the NO DOUBLE condition. If power is lost to the control the relay

is not energized and the DOUBLE contact is closed.

4. Always use shielded cable from the probe to the control module (Belden 8771 or equivalent).

The probe is connected to terminals on the rightmost terminal block labeled Red, White,

Black & Shield. Connect the shield leads (drain wires) from the probe cables to the terminals

labeled SHLD. If a splice is made between the control and probe leave the probe unshielded

no more than 20 to 30 mm.

5. The output relay may be operated in a "follower" mode or "memory" (latch or sealed) mode

depending upon the wiring of the RESET input. The mode connections and definitions are

described below.

a) To operate the output in the "follower" mode, jumper RESET and COM. together on the

terminal block. When a DOUBLE condition occurs, the relay drops out and the DOUBLE

indicator comes on. When the double metal condition is removed, the relay returns to the

normally energized condition, the yellow DOUBLE indicator goes out and the green NO

DOUBLE indicator turns on. Automatic reset is normally selected to control the operation

when the fault condition is automatically removed or the DS101 is wired into the stop circuit

of a machine with a manual restart circuit.

b) To operate the output in a "latch" mode, wire the RESET and its associated COM terminal to

the normally open contact of a switch, relay, or controller output. In this mode, when a fault

condition occurs, the relay drops out and the DOUBLE indicator comes on. After the fault

condition is corrected, the RESET contact must be momentarily activated to bring the relay

back to the NO DOUBLE state.

INPUTS AND CONTROLS

The primary control input to the DS101 is the calibration push-button switch on the front panel.

Use of this switch is described below under CALIBRATION.

The DS101 has two logic inputs labeled CAL and RESET. The CAL input parallels the function

of the calibrate push-button on the front panel allowing the calibration function to be performed

through a remotely located switch wired to this input. The RESET input controls the latching of

the relays as described in item 5 of the Electrical Wiring section above.

The two logic inputs have associated with them two jumper plugs located immediately behind

its associated terminal. The function of these jumpers is described below under

CONFIGURATION SWITCHES AND JUMPERS.

Both the CAL and RESET inputs are ON when pulled low (zero volts) independent of the jumper

settings.

A two position DIP switch to the right of the terminal blocks controls the selection of the

calibration mode and the system response time as described below under CONFIGURATION

SWITCHES AND JUMPERS.

OUTPUTS

The DS101 outputs include a form C relay for reporting OVER conditions and a dc logic output

for reporting no material in front of the probe.

The logic output is labeled the NOTHING output since it provides an indication that nothing is

present in front of the probe. The intent of this output is to signal that a sheet did not feed. This

output provides a dc sourcing signal that switches between zero volts and 22 volts, delivering up

to 100 mA.

The NOTHING output is ON (sourcing at 22 volts) when material is present in front of the probe.

INDICATORS

The function of the indicators and controls on the DS101 are described in the following

paragraphs:

During normal gauge operation, the yellow DOUBLE indicator is ON whenever the received

signal is closer to the calibrated value for double thickness than to the calibrated value for single

thickness. The green NO DOUBLE indicator is ON whenever the received signal is closer to the

calibrated single thickness value than to the calibrated double thickness value.

Through various flashing patterns, these indicators also provide information regarding system

mode (calibrate vs operate), firmware version number, and error conditions. Reading firmware

version is described later in this document. All other flash patterns can be interpreted as follows:

Alternate flashing of yellow and green indicates busy such as during initialization after power-up.

Simultaneous flashing of yellow and green indicates failed calibration. The reasons are various

such as calibration sample too thick, sample too thin, too little difference between double and

single, or too much air gap between metal and probe.

Green flashing, yellow off - awaiting single sample for calibration.

Yellow flashing, green off - awaiting push-button press for calibration on double.

Green flashing, yellow on - probe error. Probe not connected, probe wire broken, or probe is

defective.

CONFIGURATION SWITCHES AND JUMPERS

A two position switch is located on the main control circuit board at the right of the terminal

blocks. In units with version 1.3 or later firmware, the right switch determines the response time

of the system as detailed below. The right switch is not used on units with version 1.2 or earlier

firmware. The switch on the left selects one or two “hit” calibration as described below in the

CALIBRATION section of this document.

Left Switch: UP selects calibrate on single.

DOWN selects calibrate on single and double

Right Switch: UP selects standard (12 millisecond) response time.

DOWN selects high speed (2 millisecond) response time.

NOTE: These switches are read only at power up. If a switch setting is

changed, be sure to power the unit down and back up again.

Each of the logic inputs (CAL and RESET) has associated with it a two position jumper plug

located immediately behind its associated connector. These jumpers allow the inputs to be

driven by a sinking (NPN) or sourcing (PNP) device. When the jumper plug is installed on the

pins closest to the connector, the input is set up for a sourcing driver. When installed on the

two pins farthest from the connector (factory setting), the input is set up for a sinking driver, or

dry contact between the input and COM. Both inputs are active low.

CALIBRATION

The detector may be calibrated via the push-button switch on the front panel or remotely through

a switch connected between the CAL and COM terminals of the right terminal block.

The DS101 offers two modes of calibration: 1) calibrate on single nominal thickness, and 2)

calibrate on single and double thickness. Normally where double thickness discrimination is

required, the DS101 can be calibrated on a single thickness of the material to be monitored (one

press of the push button). If finer changes in thickness are to be discriminated, the DS101 may

be calibrated on two different thicknesses of the same material. The discrimination threshold is

set halfway between the two calibration points.

Calibration on Single Only (Single Hit)

Calibration on single is selected when the left configuration switch is UP. See section on

CONFIGURATION SWITCHES AND JUMPERS above.

Place a single sheet of metal to be gauged against the probe face and press the CALIBRATE

push-button. During calibration on the single thickness, the green (NO DOUBLE) indicator

flashes and the yellow (DOUBLE) indicator is off. If the calibration on the single is successful,

the green indicator stops flashing and remains solidly on until the material thickness at the probe

face changes.

If the calibration is not successful, both indicators flash simultaneously. Make sure that the sheet

is solidly against the probe and not moving when calibrating or that the sheet thickness does not

exceed the probe specification. (See probe specifications on page 2). If everything seems to

check out, re-try the calibration. Alternatively try calibrating on single and double as described

below. If difficulties persist, call Prime Controls for technical assistance.

Calibration on Single and Double (Two Hit)

Calibration on single AND double is selected when the left configuration switch is DOWN.

Place a single thickness of material against the probe face and press the CALIBRATE push-

button. During calibration on the single thickness, the green (NO DOUBLE) indicator flashes

and the yellow (DOUBLE) indicator is off. When calibration on the single thickness is complete

and the unit is ready for the double thickness, the green indicator turns off and the yellow

indicator flashes. Place a sample of thicker material or two samples of the single material against

the probe face and press the CALIBRATE push-button again. If calibration is successful, the

yellow indicator stops flashing and remains solidly on and the green indicator is off.

If the calibration is not successful, both indicators flash simultaneously. The causes for

unsuccessful calibration can be many including too little difference in thickness between the thin

and thick material, poor probe contact, non-ferrous material, wrong probe model for the material,

etc.

FIRMWARE VERSION

From time to time, as improvements are made to Prime products, the firmware controlling the

units is revised. When setting a unit up or troubleshooting it may be necessary to determine the

version number for the firmware installed in your unit. The version numbers begin with 1.0 and

are incremented either by tenths (1.1, 1.2, etc.) for small revisions or by the integer digit (1.0, 2.0,

etc.) for more significant revisions.

To determine the version of the firmware running in your unit, simply hold the calibration push

button in as power is applied to the unit. The revision number is displayed as one second flashes

of the NO DOUBLE LED for the integer digit followed by one second flashes of the DOUBLE

LED for the fractional digit. Count the number of flashes on each LED to determine the revision

number. Thus one flash of the NO DOUBLE LED followed by two flashes of the DOUBLE

LED indicates version 1.2 of the firmware.

SPECIFICATIONS

Enclosure

Material: Polycarbonate

Color: Light gray body, clear cover

Dimensions: 6.70 in. high x 4.75 in. wide x 2.17 in. deep

(170 mm x 121 mm x 55 mm)

Seal: Nema 4x

Mounting Holes: 0.175 in. diameter on 6.25 in. x 3.58 in rectangle

4.45 mm diameter on 159 mm x 91 mm rectangle

Power requirements

95 to 130 volts, 50/60 Hz at 50 mA (Suitcase jumpers A and C installed).

190 to 250 volts, 50/60 Hz at 25 mA (Suitcase jumper B installed).

Logic Input Electrical Specifications

CAL, RESET: 30 Volts maximum

Upper switch threshold - 6.9 volts

Lower switch threshold - 3.3 volts

When the internal jumper is installed for pull up to accommodate sinking drivers, the input is

pulled to +15 volts through 4700 ohms. When the jumper is installed for pull down to

accommodate sourcing drivers, the input is pulled to common through 4700 ohms.

Logic Output Electrical Specifications

NOTHING: PNP sourcing, 100mA max., 0 volts low, 22 volts high.

Output relay specifications

Maximum switched voltage: 380VAC

Maximum switched current: 14 amps N.O., 5 amps N.C, AC resistive; 8 amps DC

Maximum switched power: 200W DC, 2,000 VA AC.

Minimum required contact load: 12V, 100 mA

Expected mechanical life: 20 million operations

Expected electrical life: 100,000 operations at 8 amps, 240VAC

50,000 operations at 14 amps N.O., 5 amps N.C.,

120VAC resistive

30,000 operations at 7.2FLA, 45LRA, 120VAC

10,000 operations at 5FLA, 30 LRA, 240VAC

TROUBLESHOOTING

Should trouble develop, proceed as follows:

1. Check AC input power to the control module

2. Check the fuse, accessible at the front panel behind the clear plastic cover.

3. When powers is applied, if the green and yellow indicators show a response to the metal

condition in front of the probe and the output relay does not switch, check that the RESET

jumper is installed (if you want the relay to follow the sheet condition). The jumper is

installed between RESET and COM. on the terminal strip. If the unit is reset by an external

machine START button, check wiring across the RESET and COM terminals or the START

button contacts.

4. When power is applied, if the DOUBLE indicator is on solidly while the NO DOUBLE

indicator is flashing, check for a missing, disconnected, open, or shorted probe.

5. If both indicators flash in unison, the system is indicating an invalid calibration. The

potential causes are many. Among them, an attempt to calibrate both double and single on

the same thickness material, a shorted receiver probe, probe gap too large, incorrect probes

for the material being gauged. If the problem is not resolved, call the factory for assistance.

For further information or service assistance, contact Prime Controls, Inc., 4551 Gateway

Circle, Dayton, Ohio 45440-1711. Phone: (937) 435-8659, Fax: (937) 435-2091. Mention model

number and serial number.

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