Double Sheet Detector I100 R100 Series Double Sheet Detector

Double Sheet Detector I100 R100 Series Double Sheet Detector
Double Sheet Detector I100 R100 Series
Double Sheet Detector I100
R100 Series
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for double sided sensors
► Double sided sensors (transmitter / receiver), inductive
► Non-contact double sheet control of
FE material 0.05 - 4 mm (single sheet)
NF material 0.05 - 12 mm (single sheet)
► Suitable for fluttering sheets
► Easy setup by key operation or via control input
► LCD display for visualization of nominal / current values,
operational / error messages, key allocation
► Compact enclosure
- control unit for DIN-rail mounting, protection class IP00
- control unit for screw-on mounting, pluggable connections, protection class IP54
- control unit for screw-on mounting, in protective enclosure, protection class IP65
Copyright
©
2013 ROLAND ELECTRONIC GmbH
Otto-Maurer-Str. 17
DE 75210 Keltern
All rights on this document are at Roland Electronic GmbH.
Reproduction (also partly), electronical coverage, translation, transmission to third parties,
only with our prior permission.
Subject to change without further notice.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
Table of contents
Declaration of conformity according to EC directives .....................................................................................5
1
Safety advices ........................................................................................................................................7
1.1
General..............................................................................................................................................7
1.2
Safety instructions and warnings for user .........................................................................................7
2
Technical data ........................................................................................................................................9
2.1
Control unit I100................................................................................................................................9
2.2
S/E sensors .....................................................................................................................................12
2.2.1
Sensor S/E 28.............................................................................................................................12
2.2.2
Sensor S/E 34.............................................................................................................................12
2.2.3
Sensor S/E 34V_16kHz ..............................................................................................................12
2.2.4
Sensor S/E 54.............................................................................................................................12
2.2.5
Sensor S/E 75.............................................................................................................................12
2.2.6
Sensor MSI18S/E .......................................................................................................................12
2.3
Technical drawing S/E sensors.......................................................................................................13
2.3.1
Sensor diagrams.........................................................................................................................14
2.3.2
Cable allocation of S/E-sensors and sensor cables KISS and KISE..........................................15
2.3.3
Cable allocation of MSI18S/E-sensors and cables KMSISS and KMSISE ................................16
3
System description ..............................................................................................................................17
3.1
Introduction .....................................................................................................................................17
3.2
Structure and measuring principle ..................................................................................................17
3.3
Functional sequence .......................................................................................................................18
4
Mounting ...............................................................................................................................................19
4.1
Mounting of the control unit.............................................................................................................19
4.2
Mounting of the sensors..................................................................................................................19
4.2.1
Mounting the MSI18S/E-sensors ................................................................................................20
4.2.2
Measurement target....................................................................................................................21
4.3
Cables .............................................................................................................................................22
4.3.1
Sensor cables .............................................................................................................................22
4.3.2
Power supply / Control cables ....................................................................................................22
5
Electrical installation ...........................................................................................................................23
5.1
Connecting diagram for I100 and I100-IP65 ...................................................................................24
5.2
Connecting diagram for MSI18S/E-sensors....................................................................................25
5.3
Connections at I100-S.....................................................................................................................26
6
Start-up..................................................................................................................................................29
6.1
Keys and indicators.........................................................................................................................29
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3
Manual
Double Sheet Detector R100 I100
for pairs of sensors
Table of contents
B0003308 / 1.4 / 13.02.2013
6.2
Allocation and function of keys....................................................................................................... 29
6.3
Switching on and Powering up ....................................................................................................... 30
6.4
Operational conditions.................................................................................................................... 30
6.4.1
Undisturbed operation................................................................................................................ 30
6.4.2
Detection of 0-sheet, 1-sheet or 2-sheet.................................................................................... 30
6.4.3
Operational disturbances ........................................................................................................... 31
6.4.4
Functional check ........................................................................................................................ 31
6.5
Measurement mode ....................................................................................................................... 32
6.6
Teach-In ......................................................................................................................................... 33
6.7
Changing the switching thresholds................................................................................................. 34
6.8
Teach-In with changed threshold values........................................................................................ 36
6.9
External Teach-In ........................................................................................................................... 37
7
Fault messages, causes and remedies ............................................................................................. 39
8
Maintenance......................................................................................................................................... 41
9
Order data ............................................................................................................................................ 43
4
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
Safety advices
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Declaration of conformity according to EC directives
Manufacturer:
Roland Electronic GmbH
Otto-Maurer-Str. 17
DE 75210 Keltern
Product name:
I100
Product type:
R100 Double Sheet Detector
Roland Electronic GmbH declare that the product listed above complies with the requirements of
the EMC directives listed below.
Applied Directives:
2004/108/EG:
EMC Directive
EN61000-6-2: 2005-08
EN61000-6-4: 2007-01
Date of mark’s apposition: 13.02.2013
Keltern, 13.02.2013
Place, Date
Managing Director
Signature
Function of the signer
The declaration confirms the compliance with the cited directives. However, it is not any implied warranty of fitness for a
particular purpose especially as it may relate to product liability.
The safety instructions and warnings must be observed.
DIN EN ISO 9001
Reg.-no. 5152
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Safety advices
Blank page
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6
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
1
Safety advices
Safety advices
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1.1
General
This document was created with utmost care. Anyhow, faults and cases of misunderstanding
cannot be totally excluded. Please contact us in case of differences or weak understanding. We will
be pleased to assist you.
We reserve the right to improve this document at any time without announcement. No exchange of
delivered documents.
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1.2
Safety instructions and warnings for user
This handbook contains all information required for the correct operation of the Roland equipment.
It has been written for technically qualified personnel.
Unauthorized tampering with the unit, especially ignoring the warnings in this handbook, can cause
malfunction and damage to the unit. Only authorized personnel should be allowed to make
changes to the unit and perform cable connections especially the power supply.
Should it be necessary, e.g. in case of service or repair, to make measurements within the unit,
then all customary accidents prevention procedures should be observed. Only professional
electrical tools should be used.
Note
The factory pre-settings – especially the upper / lower limit values – have
been chosen such that an optimal machine protection is ensured.
Diverging settings can impair the machine protection.
Safety advice for persons with cardiac pacemakers!
Persons with cardiac pacemakers are to stay away from the sensors!
The strong magnetic / electromagnetic fields of the sensors can cause malfunction
of cardiac pacemakers and other such apparatus!
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Safety advices
Blank page
8
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
2
Technical data
Technical data
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Control unit I100
Supply voltage
24 V DC / 110 mA
Power consumption
approx. 2 VA
Fuse
375 mA slow-blow size 1206 (SMD)
Power / switching indication
5 LEDs
Display
LCD display, 2 lines, 16 chars. each
Ambient temperature
0° - 50°C (32° - 122°F) during operation
Opto coupler outputs, output sourcing (PNP)
Temperature depending drift of switching point
± 0,02 % / °C
Switching capacity
max. 50V, max. 10mA
Measurement period
The min. dwell time of the sheet between the sensors roughly
equals the sensor diameter in milliseconds, e.g. for S28 = 30 ms..
Enclosure
for DIN-rail mounting (EN50022, BS5584)
Class of protection I100 / I100-S / I100-IP65
IP00 / IP54 / IP65
Weight
approx. 0,2 kg (0.44 lbs)
Connections
Terminal block (I100 / I100-IP65) / Plug connection (I100-S)
Dimensions
125,4 × 103 × 38 mm (H × W × D)
125,4
Switching outputs 0-1-2 - Sheet
fault
power
2 sheet
1 sheet
0 sheet
103
46,5
2.1
Fig. 1: Dimensions of I100 (for mounting on DIN-rail)
I100 abmessungen.wmf
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Technical data
Description
30
Deckel / Lid
90
1 Screw fitting M16
for control cable
Wrench size 19 mm
M12×1,5
SW 15
M12×1,5
SW 15
3 Screw fitting M12
for sensor cable (receiver)
Wrench size 15 mm
40
M16×1,5
SW 19
2 Screw fitting M12
for sensor cable (transmitter)
Wrench size 15 mm
114
2 sheet
1 sheet
0 sheet
fault
power
1
38
3
2
35
63
4,2 Ø
120
Fig. 2: Dimensions of I100-IP65 (in protective enclosure IP65)
10
154
135
148
160
90,5
I100 in multibox IP65.wmf
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
Technical data
37
Description
To connect the connection
cables a clearance of 120mm
is required.
155
137
122
73,5
105
130
Ø4,5mm
Freiraum für
Kabel und Stecker
120
29
8
Clearance for
Cables and plugs
Fig. 3: Dimensions of I100-S
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Technical data
2.2
S/E sensors
The sensors are available either with fixed cable or plug connector.
The pluggable version has the addition S (e.g. S/E28 -> S/E28S)
For all sensors: Class of protection:
Length:
Ambient temperature:
Single sheet thickness:
2.2.1
IP65
transmitter 65 mm, receiver 45 mm
0 – 50 °C during operation)
see sensor diagrams
Sensor S/E 28
Technical data
2.2.2
Responding time:
30 ms
Diameter:
28 mm (1.1 inch)
Weight:
0,28 kg (0.62 lbs)
Sensor S/E 34
Technical data
Responding time:
2.2.3
35 ms
Diameter:
34 mm (1.34 inch)
Weight:
0,40 kg (0.89 lbs)
Sensor S/E 34V_16kHz
Technical data
Responding time:
2.2.4
35 ms
Diameter:
34 mm (1.34 inch)
Weight:
0,40 kg (0.89 lbs)
Sensor S/E 54
Technical data
2.2.5
Responding time:
55 ms
Diameter:
54 mm (2.13 inch)
Weight:
0,90 kg (1.99 lbs)
Sensor S/E 75
Technical data
Responding time:
2.2.6
75 ms
Diameter:
75 mm (2.96 inch)
Weight:
1,80 kg (3.97 lbs)
Sensor MSI18S/E
Technical data
Responding time:
30 ms
Diameter:
18 mm (0.71 inch)
Weight:
0,18 kg (0.40lbs)
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12
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
Technical drawing S/E sensors
Description
Ø 28
2.3
Technical data
Ø 75
Ø 54
Ø 34
The sensors S/E28, S/E34,
S/E54, S/E75 are equipped with a
firmly connected cable for terminal
connection. Standard cable length
is 2 meters, lengths up to 20
meters upon order.
65 mm
45 mm
Sender
Transmitter
Empfänger
Receiver
M S I1 8 S /E
Ø M18
Ø 20
The sensors S/E28S, S/E34S,
S/E54S, S/E75S are without
cable, but with build-in plug at the
sensor.
The sensors MSI18S and MSI18E
are without cable, but with build-in
plug at the sensor.
52,5
10
75
Fig. 4: Dimensions of S/E sensors and MSI18S/E sensors
Maßbild Sensoren SE28 bis SE75.wmf
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Technical data
2.3.1
Sensor diagrams
The marked areas represent the working ranges of the sensors. For all combinations of sheet
thickness and sensor distance Ax within the range a double sheet condition will be securely
detected, if the switching thresholds are set “tight”. So it might be required to restrict the 1-sheet
detection range by changing the (factory-set) thresholds of 85% / 115% to approx. 95% / 105%.
The working ranges of the sensors depend very much on the material properties, they can deviate
from the sensor diagrams shown below.
mm
mm
S/E28
S/E34
40
15
Ax
Ax
30
AL
10
AL
20
FE
5
10
0
1
2
0
mm
3
1
2
3
4
Blechdicke
Sheet thickness
mm
S/E34V
40
30
AL
30
Nicht magnetischer
Edelstahl (INOX)
20
Ax
FE
20
Non-magnetic
Stainless steel (INOX)
10
10
0
1
2
3
4
0
5 mm
2
4
6
8
10 mm
Blechdicke
Sheet thickness
Blechdicke
Sheet thickness
mm
6 mm
S/E54
mm
40
Ax
5
Blechdicke
Sheet thickness
S/E75
MSI18E/S (5KHz)
mm
60
40
50
Ax
40
AL
Ax
FE
30
0
AL
30
20
2
4
6
8
10
12
14 15 mm
Blechdicke
Sheet thickness
0
1
1,5
2
2,5 mm
Blechdicke
Sheet thickness
Fig. 5: Sensor diagrams for S/E sensors and MSI18S/E sensorsensordiagramme-S28-S75-deu-eng.wmf
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14
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
Cable allocation of S/E-sensors and sensor cables KISS and KISE
For sensors and cables before February 2008
For sensors and cables before February 2008
S…
Transmitter
1×2×0,25mm2 (pair-wise twisted)
brown
white
blank (shield)
E…
Receiver
1×2×0,25mm (pair-wise twisted)
brown
white
blank (shield)
2
KISS
S…S
Transmitter
1×2×0,25mm2 (pair-wise twisted)
KISE
E…S
Receiver
1×2×0,25mm2 (pair-wise twisted)
Fig. 6: Cable allocation of S/E sensors and sensor cables before february 2008
Sensoren_deu.wmf
Note:
blank (shield) [3]
white [2]
brown [1]
white [3]
blank (shield)
brown [1]
Kabelbelegung_SE-
S/E sensors with black cables should no longer be used.
For sensors and cables after February 2008
For sensors and cables after February 2008
2.3.2
Technical data
S…
Transmitter
E…
Receiver
3×0,25mm
2
2×0,25mm2
S…S
Transmitter
KISS
E…S
Receiver
KISE
3×0,25mm2
2×0,25mm2
Fig. 7: Cable allocation of S/E sensors and sensor cables after February 2008
brown
white
green
blank (shield)
brown
white
blank (shield)
brown (1)
white (2)
green (3)
blank (shield)
brown (1)
white (3)
blank (shield)
Kabelbelegung_SE-Sensoren_deu.wmf
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Technical data
2.3.3
Cable allocation of MSI18S/E-sensors and cables KMSISS and KMSISE
3
MSI18S
KMSISS-G
2
4
5
2
1
3
KMSISE-G
optional with straight receptacle or
right angle receptacle
Fig. 8: Cable allocation of MSI18S/E-sensors and sensor cables
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16
2 = green
3= brown
1
MSI18E
1 = white
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1
2
3
4
5
= white
= green
= brown
= yellow
= shield
Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
3
System description
System description
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3.1
Introduction
When automatically feeding sheets from a stack to a processing machine, it can unintentionally
happen that more than one sheet is picked up and transported. This can result in disturbances of
the machine run, damage of tools, expensive repair measures and loss of production. The A100
double sheet detectors can reliably prevent from such incidents by measuring the thickness of
every sheet from both sides with a pair of sensors.
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3.2
Structure and measuring principle
A system mainly consists of the control unit, the sensor and the sensor cable.
For performing the measurement, the transporting facility of the machine must move the sheet
between the sensors. During the measurement the sensors do not contact the sheet.
The transmitter emits an alternating electrical field, the receiver on the other side of the sheet
electronically detects the signal attenuated by the sheet. The receiver signal is processed in the
control unit and made available to the machine control as switching signals.
The main influencing factors for the measurement are the material properties of sheets, the sensor
bracket (holder), the sensor distance and the neighbouring metal parts.
Caution!
The system is not suited for applications
of personal protection!
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
System description
3.3
Functional sequence
The transport facility places the sheet between the sensors. The receiving sensor will process the
transmitted sensor signal. According to the preset limits, the respective signal output
(0-sheet, 1-sheet, 2-sheet) will be set activated.
If the output signal for 2-sheet is active, the PLC stops the material transport for removal of the
double sheet.
Note!
“Active“means, that the signalling output will switch. In case that the
supply voltage fails, all signalling outputs (0-, 1-, 2-sheet) will become
inactive.
Then the PLC must stop the material transport.
Caution!
Usually, the signalling outputs of the control unit will be used for
stopping the material transport facilities and / or machines in case of
double sheet.
As soon as the double sheet is removed from the sensor(s), the
signalling outputs instantly switch back to normal condition (0-sheet /
1-sheet).
Suitable control measures must ensure that the previously stopped
material transport facilities and / or machines cannot automatically
restart and thus create hazardous situations.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
4
Mounting
Mounting
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4.1
Mounting of the control unit
The system is available in 3 different enclosures:
•
for machine mounting, cables pluggable, in metal enclosure,
protection class IP54.
•
for DIN-rail mounting (EN50022, BS5584), protection class IP00.
•
for machine mounting, in plastic enclosure with transparent lid,
protection class IP65.
The system should be mounted in such a way that the indicators and operating keys in the front of
the unit are always well visible. The place should be safely accessible and free from obstruction.
The system must not be exposed to extreme temperature, irradiation or mechanical load.
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4.2
Mounting of the sensors
Caution!
The sensors must be kept away from magnet sensitive
media (cheque cards, hard disks, diskettes…) and
systems (cardiac pacemakers, solenoid switches).
Sensors with different sizes are available. The size has substantial influence on the thickness
measuring range.
Mounting:
The place of mounting depends on the transporting equipment. In principle a distance of more than
0.5m must be kept from magnetic/electromagnetic interference sources like e.g. valve coils,
transportation magnets, inductive proximity switches or the like.
The sensors can be mounted in any direction, transmitter and receiver must be aligned face-toface. The possible distance (Ax) of the sensors can be read from the sensor diagrams.
•
It is recommended to mount the sensors in “stick-out” position in brackets made of plastic or
stainless steel.
•
Flush mounting is also possible, then however only in brackets made of plastic material.
•
Recessed installation is very unfavourable, particles and splinters can accumulate in the recess.
•
Sensor brackets made of electrically well conductive NF metals (aluminum, copper, brass)
should not be used, since otherwise the sensor distances must be reduced (see sensor
diagrams).
Length and width of the sheet to be controlled should be at least 3 × the sensor diameter. Then
safe double sheet control is ensured.
The minimum retention time of the sheet between the sensors (full surface coverage) up to
switching the appropriate exit depends on the sensor diameter. The minimum retention time (in
milliseconds) corresponds roughly to the sensor diameter. Something similar applies to the
minimum measuring break between 2 sheet metals up to switching the appropriate exit.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Mounting
4.2.1
Mounting the MSI18S/E-sensors
Preferably the sensors should be mounted either in sturdy plastic or nonmagnetic stainless steel
brackets.
The transmitter and receiver should be mounted aligned to each other with a sensor gap specified
in the documentation. Sensors should not be mounted flush in the bracket and recessed mounting
should also be avoided in order to prevent accumulation of metallic chips and dirt.
Protruded sensor mounting according to examples "A" or "B" is recommended. Brackets made of
aluminum or other nonferrous metal with high electrical conductivity should be avoided in order to
prevent performance degradation and reduction in sensor gap Ax.
Measuring legend:
Example A
D: sensor diameter
B
B: min. 10 mm
Ax: agreed sensor distance, see sensor diagram
B
Ax
D
>D
D
>D
B
Ax B
Example B
Fig. 9: Mounting the MSI18S/E-sensors
20
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
4.2.2
Mounting
Measurement target
The sensor coverage (measurement target) must be at least the three times sensor diameter. The
dimension x should ideally correspond to the sensor diameter D (see picture below).
If the coverage is smaller, then the sheets should be transferred with reduced speed through the
sensor gap or measured statically. Precondition is however a constant distance to the sheet edge.
h
ec
Bl
D
h
/S
t
ee
x
x
Sensor
Fig. 10: Measurement target
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Mounting
4.3
Cables
All cables must be professionally installed. Bending radii (see data sheets of manufacturer) must
be adhered. The cables must be protected from chafing and buckling by suitable installation.
Damaged cables must not be used and need to be replaced immediately.
If the recommended cables cannot be used (e.g. due to missing UL/CSA approval), substitutes
should be cleared with Roland Electronic.
Note!
4.3.1
Keep the sensor cables as well as the power supply / control cable
away from unshielded cables with strong electro magnetical
interference potential (e.g. servo motor and power cables).
Sensor cables
The sensors are available either with plug connector or with fixed cable. For connecting, only the
supplied shielded sensor cables may be used. In the standard version those cables are suitable for
drag-chain operation but not for robot operation.
The cable shield is connected at both sides.
4.3.2
Power supply / Control cables
Suitable power supply / control cables:
- Type H05VV5-F (Lapp Ölflex® 140) with leads 0.5 mm²
- Type H05VVC4V5-K (Lapp Ölflex® 140CY), shielded, with leads 0.5 mm².
A shielded cable must be used if the environment has high electromagnetical interference signals.
This cable shield must be grounded at the machine side, not at the control unit side.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
5
Electrical installation
Electrical installation
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The system should be installed only by professional electricians. The cables must correspond with
the specifications stated in section „Cables“.
Note!
For connecting the cables to the
control unit, insulated wire-end
ferrules must be used.
The required supply voltage is 24 V DC and should be supplied from the associated machine
controls.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Electrical installation
5.1
Connecting diagram for I100 and I100-IP65
– 12V
weiss / white
GND
Schirm / shield
braun / brown
Schirm / shield
+ 12V
V in
weiss / white
braun / brown
+24V COMMON
0-Blech / 0-sheet
1-Blech / 1-sheet
2-Blech / 2-sheet
Teach-In
GND
+24 V
zum Sensor / Sender
to sensor / transmitter
zur SPS
to PLC
zum Sensor / Empfänger
to sensor / receiver
– 12V
weiss / white
GND
grün / green
braun / brown
Schirm / shield
+ 12V
V in
weiss / white
braun / brown
+24V COMMON
0-Blech / 0-sheet
1-Blech / 1-sheet
2-Blech / 2-sheet
Teach-In
GND
+24 V
grün-gelb
PE green-yellow
V
in
Für Sensoren bis Februar 2008
For sensors before February 2008
Schirm / shield
grün-gelb
PE green-yellow
V
in
For sensors before February 2008 and after February 2008
zum Sensor / Sender
to sensor / transmitter
zur SPS
to PLC
Für Sensoren ab Februar 2008
For sensors after February 2008
Note!
zum Sensor / Empfänger
to sensor / receiver
The shielding of the cable must always be connected.
The protective lead (PE) must always be connected,
it may never be missing.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
Electrical installation
Internal circuit of the PLC connection (terminals 4 to 8)
Fig. 11: Connecting diagram for I100 and I100-IP65
Connecting diagram for MSI18S/E-sensors
9
10
11
12
13
14
+24V
GND
-12V
15
16
17
18
shield
green
white
brown
white
yellow
to receiver
shield
gr
ee
n
br
ow
n
5.2
I100 a
to transmitter
Fig. 12: Connecting diagramm for MSI18S/E-sensors
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Electrical installation
5.3
Connections at I100-S
1
2
3
1
2
Supply socket
Sensor socket f. receiver
Sensor socket f.
transmitter
3
Fig. 13: Connections I100-S
Supply socket (pos. 1)
view onto contacts
Socket at unit
Supplier / types / remarks
Enclosure HAN 3A, EMI-type, metrical
7-pin insert with PE, Pin contacts at control unit
Harting and others
Pin1
+24V DC
Internal Pin 2
Pin 2
common / GND
Internal Pin 3
Pin 3
Teach-In
Internal Pin 4
Pin 4
2-sheet
Internal Pin 5
Pin 5
1-sheet
Internal Pin 6
Pin 6
0-sheet
Internal Pin 7
Pin 7
+24V DC f. I/O
Internal Pin 8
Pin 8
PE
Internal Pin 1
The associated cable plug (contacts) is not within the scope of delivery, it must be ordered separately under S0003515.
See also chapter ”Order data“.
Sensor socket f. receiver (pos. 2)
3
1
view onto contacts
Socket at unit
Supplier / types / remarks
M12, 2-pin, B-coded,
female connector at control unit
Binder Type 713 and others
Pin 1
+Vin
Internal Pin 10
Wire colour: brown
Pin 2
-Vin
Internal Pin 11
Wire colour: white
Enclosure
Shield
Internal Pin 14
transparent / green-yellow
Sensor socket f. transmitter (pos. 3)
1
3
2
view onto contacts
Pin 1
Socket at unit
Supplier / types / remarks
M12, 3-pin, B-coded,
female connector at control unit
Binder Type 713 and others
+12V
Internal Pin 15
Wire colour: brown
Pin 2
-12V
Internal Pin 17
Wire colour: white
Pin 3
common / GND
Internal Pin 16
Wire colour: green
Shield
Internal Pin 18
transparent / green-yellow
Fig. 14: sockets I100-S
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
Electrical installation
Sensors and cables
The sensors with pluggable cable
S…S (transmitter) and
S…E (receiver)
require the cables
SKOISS-GG (transmitter) and.
SKOISE-GG (receiver)
for operation with the I100-S.
For operating the sensors S…
(transmitter) and E… (receiver) with firmly
attached cable and open wire ends at the
I100-S the plug 2277707 must be attached
at the transmitter cable and the plug
2277706 at the receiver cable, according
to the illustration below.
Both plugs can be ordered as set under
S0003517, but can also be ordered
separately.
I100-S
SKOISS-GG
Transmitter
S...S
SKOISE-GG
Receiver
E...S
2277707
Transmitter
S...
Receiver
E...
I100-S
2277706
Fig. 15: Sensors and cables for I100-S
Sensor plug for receiver (2277706)
3
1
view onto soldering side
Pin 1
+Vin
wire colour: brown
Pin 3
-Vin
wire colour: white
enclosure
shield
transparent / green-yellow
Pin 1
+12V
wire colour: brown
Pin 2
-12V
wire colour: white
Pin 3
common / GND
wire colour: green
enclosure
shield
transparent / green-yellow
Sensor plug for transmitter (2277707)
1
3
2
view onto soldering side
Fig. 16: Allocation of sensor plugs for I100-S
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Electrical installation
Blank page
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
6
Start-up
Start-up
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6.1
Keys and indicators
The control unit has three operating keys, which provide for easy adjustment.
Adjustment is required upon commissioning and change of material.
Description
1
2
fault
power
3
2 sheet
1 sheet
0 sheet
1
LCD display
2
Operating keys
3
LEDs for condition of unit
FAULT
malfunction
POWER
power supply
4
LEDs for switch conditions
2-Sheet
1-Sheet
0-Sheet
4
Fig. 17: Controls and indications
6.2
Allocation and function of keys
The functions of the 3 operating keys are variable, as will be shown in the lower line of the display.
For example, the operator can change from the
measuring mode into the setup mode with the key
“setup”.
Fig. 18: Indication of key allocation
Note!
R100structure.bmp
If a function causes a fault, a fault number is indicated and the yellow
LED "FAULT" lights.
The error condition can be confirmed with the right "ENTER" key.
Otherwise the system changes to the measuring mode after approx 5
seconds. The “FAULT” LED will, however, go off only if upon a new
attempt the requested function is fault free.
If a function consists of several steps, which are not completely
executed, the system automatically changes back to the original
measuring mode after approx. 5 seconds.
Dummy I100-2.jpg
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Start-up
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6.3
Switching on and Powering up
Applying the supply voltage (24 V DC) to the unit will switch the unit on, as soon as power is
supplied the POWER LED lights.
When the operation system is loaded, the manufacturer and system information will be shown for a
short period.:
Roland
Electronic GmbH
and then
A100 (I100 for system I100)
Sw.1.0 21.05.2007 1
Fig. 19: Indication of manufacturer and system information
The unit changes automatically to the measuring mode and will work with the last taught values.
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6.4
Operational conditions
6.4.1
Undisturbed operation
As long as no fault is detected in the measuring mode, no operator actions are required.
The unit measures continuously and sets the signal output according to the measurement result.
6.4.2
Detection of 0-sheet, 1-sheet or 2-sheet
As long as the measured value is within the range of 85% to 115% of the nominal value, the
system will detect 1-sheet.
If the measured value is outside the range, the system will then detect 0-sheet (no sheet)
or 2-sheet (double sheet).
1
•
The associated LED (0-SHEET, 1-SHEET, 2-SHEET) will light up accordingly.
•
The associated signal output will be set to low resistance (active).
•
The signal outputs 0-SHEET, 1-SHEET, 2-SHEET will deliver a switch voltage only if an
external positive voltage (max. +24V, min. 50mA) is applied to the COMMON input (terminal 8).
Depending on software version
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
6.4.3
Start-up
Operational disturbances
If situations arise during operation, which the system recognizes as "operational faults", the system
reacts with the “FAULT” LED lighting and issues the assigned fault message (if any).
• If the fault condition was caused by the machine PLC, the signal outputs for 1-sheet
and 2-sheet are set at the same time. The illogical constellation of 1-sheet and 2-sheet will
indicate the fault condition to the machine PLC. Depending upon the PLC programming an
appropriate reaction can then be initiated. Recognizable faults are to be eliminated and the
function should be performed again.
• If the fault condition was caused by the operator or by the system, the operator must react
according to the measures explained in the fault table.
• If the fault cannot be assigned, restarting the system by recycling power may eliminate the fault.
6.4.4
Functional check
If the system does not detect double sheet conditions though a Teach-In was freshly performed,
the sensorics might (according to material properties) work at the detecting limit.
First, the mechanical sensor settings should be checked, as well as the working range (according
to sensor data).
If the mechanical circumstances are correct and the sensor is operated within the permissible
range, the upper limit might be improved by changing the upper threshold. For doing so, refer to
section “changing the thresholds”.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Start-up
6.5
Measurement mode
After having applied power, the following will be displayed on the LCD display:
Fig. 20: Indication in the measurement mode
100Teach-In.bmp
In the measurement mode the current measurement value and the switching thresholds will be
shown.
Axxxx
The input signal of the sensor is represented as digital value between 0000 and 1024
this value is equivalent to the relative thickness of the material. A possible result may
look like this: 0.5 mm steel A=0300; 1.0 steel A=0590
Lxxx
Lower absolute threshold (0-999)
Uxxx
Upper absolute threshold (0-999)
The relation between material thickness and digital value depends on the sensor selected and is
not exactly linear. The nonlinearity is influenced by the type of material. During “teach-in” the input
amplifier can adopt its amplification factor and this results in a different digital value. Example for
this influence: Material A with thickness 1 mm may show 0400 after “teach-in”. Material B with
thickness 1.5 mm may show 0300 as digital value after “teach-in”.
Since the display shows the actual measurement value as well as the set switching thresholds, it
can easily be checked whether the thresholds are correctly set.
2-sheet threshold:
The threshold for 2-sheet should be selected such that it is located slightly above the normal
variation range for 1-sheet, but will be significantly exceeded in case of 2-sheet so that 2-sheet will
be securely detected.
0-sheet threshold:
The threshold for 0-sheet should be selected such that it is located slightly below the normal
variation range for 1-sheet, but will be significantly exceeded in case of 0-sheet so that 0-sheet will
be securely detected.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
6.6
Start-up
Teach-In
This function is useful in case of changing material or upon initial commissioning.
The system is in the measurement mode.
Attention! The function must not be used, if threshold values other than the
standard values (85% / 115%) are used. This function deletes the
modified values and uses the standard values instead.
Preparation:
A100: Place the sensor on the sheet.
I100: Place the sheet between the sensors.
Step 1
Push the key “setup“.
Fig. 21: Calling up the setup mode
R100structure.bmp
Step 2
Push the key “new“.
The current measurement value will now be stored as reference value.
From this value the absolute thresholds L (lower limit) and U (upper
limit) will be calculated with the factors 85% und 115% and then be
stored also.
If the function is performed, the system automatically changes back to
measuring mode and shows the new switching thresholds.
If the function could not be performed, a fault message will be shown in
the LCD display.
Fig. 22: Storing the current measurement value as reference value
Note!
Step 3
R100Teach-InHandNew.bmp
If the Teach-In fails, the previous thresholds stay active. The yellow
“FAULT” LED lights until the next Teach-In is successfully performed.
Final inspection, it must be performed after every Teach-In !
 Apply a double sheet repeatedly and check if the double sheet will be detected in any case.
 If the double sheet will not be safely detected, restrict the switching thresholds (see section
„Changing the switching thresholds“).
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Start-up
6.7
Changing the switching thresholds
This function should only be performed, if the factory-set values for the thresholds (85% and 115%)
cannot be used.
Note!
Preparation:
If this function is executed, the external Teach-In will also work with
the changed values.
A100: Place the sensor on the sheet.
I100: Place the sheet between the sensors.
Step 1
Press the key ”setup“.
Fig. 23: Calling up the setup mode
R100structure.bmp
Step 2
Press the key ”change“.
Fig. 24: Calling up a change
34
R100TChHandChange.bmp
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13.02.2013
Start-up
Step 3
Press the key “value“.
Pressing the key “value“ enables editing of the thresholds for L and U.
Editing is done with the absolute values, based on the current
measurement value.
Fig. 25: Enabling editing
R100TChangeHand+.bmp
Step 4
The sign “!“ before “L“ indicates that the value L can be changed.
The key “-“ decreases the L value,
the key “+“ increases the value.
Fig. 26: Changing the lower threshold value L
R100TChangeHandvalue.bmp
Step 5
Select the parameter U with the key “next“.
The sign “!” closes up to the “U“.
The key “-“ decreases the L value,
the key “+“ increases the value.
Fig. 27: Selecting the upper threshold value U and changing the value
R100TChangeHandNext.bmp
Step 6
Closing the setting:
With the key „exit“ the values are stored. The system changes over to the measurement mode. The
changed thresholds will be used from now on.
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Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Start-up
6.8
Teach-In with changed threshold values
This function should only be performed if different threshold settings are to be used.
Preparation:
A100: Place the sensor on the sheet.
I100: Place the sheet between the sensors.
Step 1
Press the key “setup“.
Fig. 28: Calling up the setup mode
R100structure.bmp
Step 2
Press the key “change“.
Fig. 29: Calling up a change
R100TChHandChange.bmp
Step 3
Press the key “renew“.
By pressing the key “renew” the Teach-In will be performed with the
modified settings.
The current measurement value is stored as reference value.
Based on the reference value the absolute values for the thresholds L
and U are calculated with the modified relative factors and be stored
also.
Fig. 30: Performing the Teach-In with modified values
R100TChangeHandRenew.bmp
Has the function been executed, the system automatically changes to the measurement mode and
shows the new thresholds.
If the function could not be executed, a fault message appears in the LCD display.
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Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
6.9
Start-up
External Teach-In
External Teach-In is useful, if the control unit is not mounted at the place of measurement but
inside the control cabinet, and the material will be frequently changed.
The external Teach-In can be triggered via the machine PLC or with a simple pushbutton.
Note!
Preparation:
Before the external Teach-In can be performed, a Teach–In must
once have been performed at the control unit via operating keys.
A100: Place the sensor onto the sheet.
I100: place the sheet between the sensors.
Step 1
Switch the input “Teach-In“ (terminal 4) to GND for a short time (see section “connection diagram“).
After that the signal outputs “1-sheet“ AND “2-sheet“ activated as feedback.
Step 2
Again switch the input “Teach-In“ (terminal 4) to GND for a short time. The teach-In will then be
performed.
If the Teach-In was successful, the system releases the measurement result “1-sheet“ and
automatically switches over to the measurement mode.
Note!
If the second step is not performed, the system reverts back to the
measurement mode after approx. 5 seconds without any changes.
If the Teach-In was not successful, the signal outputs “1-sheet“ and “2-sheet“ will stay active for the
present. Furthermore, an error message will be shown on the LCD indication and the yellow
“FAULT” LED will be actuated.
The error message will disappear after approx. 5 seconds, and the outputs “1-sheet“ and “2-sheet“
will be de-activated. The system then automatically reverts back to the measurement mode.
Measurements are performed with the currently existing Teach-In value.
The “FAULT” LED will go off only if a new Teach-In has been successful or if the system is restarted by recycling power.
Note!
The external Teach-In will always be performed with the last valid
thresholds.
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37
Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Start-up
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ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
7
Fault messages, causes and remedies
Fault messages, causes and remedies
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Message
Meaning
Cause / Remedy
Error 1
Value for Teach-In is not plausible
(measurement value is smaller than 25
or larger than 960)
Sensor has no contact with the sheet
Sensor cable is cut off
Sensor type is not suitable
System might be defective
Error 2
Value for external Teach-In is not
plausible
(measurement value is smaller than 25
or larger than 960)
Sensor has no contact with the sheet
Sensor cable is cut off
Sensor type is not suitable
System might be defective
Error 3
External Teach-In is not permitted
(system is still in factory-set condition)
Factory settings have not been
overwritten – perform Teach-In via
operating keys once.
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ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
39
Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Fault messages, causes and remedies
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40
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
8
Maintenance
Maintenance
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During operation, chips and metal particles can accumulate at the sensors. Thus the sensors must
be cleaned from time to time.
During operation, the sensors do not touch the sheets, so normally there will be no wearing to the
sensors. If, however, the sensors are exposed to mechanical strain for any reason (abrasion,
damage of sensor face), they must be replaced if the sensor faces begin to show small punctures.
A pair of sensors and a sensor cable should be kept on stock as spare parts.
When ordering spare parts, always state the serial number, the order information and the part
number (if available).
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ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
41
Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Maintenance
Blank page
42
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 /
13.02.2013
9
Order data
Order data
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Control units, for pairs of sensors (transmitter / receiver)
Order information
I100
I100-S
I100-IP65
Comment
Control unit, supply voltage is 24 V DC.
Control unit, for pluggable sensors supply voltage is 24 V DC, enclosure with
protection class IP54.
Control unit, supply voltage is 24 V DC, mounted in a protective enclosure with
protection class IP65.
Sensors
Order information
S/E28
S/E34
S/E34V_16kHz
Comment
Pairs of sensors, fixed cable with open wire ends for terminal block wiring.
Standard cable length is 2 meters, lengths up to 20 meters made to order.
When using those sensors with the system I100-S, mount the plug 2277707 at the
transmitter cable and the plug 2277706 at the receiver cable. Please order those
plugs separately.
S/E54
S/E75
S/E28S
S/E34S
S/E34VS_16kHz
Pairs of sensors, with plug connector for connecting the sensor cable (order cable
separately).
When using those sensors with the system I100-S, please use the cables SKOISS
and SKOISE.
S/E54S
S/E75S
Pairs of sensors, with plug connector for connecting the sensor cable (order cable
separately).
MSI18S/E
When using those sensors with the system I100 and I100-IP65, please use the
cables KMSISS-G and KMSISE-G.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
43
Manual
Double Sheet Detector R100 I100
for pairs of sensors
B0003308 / 1.4 / 13.02.2013
Order data
Cables (for connecting pluggable sensors)
Order information
Comment
KISS-G
For connecting the transmitter, only for systems I100 and I100-IP65
KISE-G
For connecting the receiver, only for systems I100 and I100-IP65
KMSISS-G
For connecting the transmitter, only for systems I100 and I100-IP65
KMSISE-G
For connecting the receiver, only for systems I100 and I100-IP65
SKOISS
For connecting the transmitter, only for system I100-S
SKOISE
For connecting the receiver, only for system I100-S
S0003517
S0003515
Plug set, for sensor cables with open wire ends, consisting of:
- 2277707 plug, for transmitter cable
- 2277706 plug, for receiver cable
The plugs can also be ordered separately.
Supply plug set, complete, consisting of:
- 2279013 sleeve enclosure
- 2276001 socket insert
- 2278003 8 pcs. socket contact 0,5mm²
- 2291011 screw fitting PG11
The parts of the plug can also be ordered separately.
Standard cable length is 2 meters, lengths up to 20 meters upon order, larger lengths upon request.
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