Baumer BA Scatec10 15 User Manual
SCATEC-10 / 15
Laser Copy Counter
FLDM 170G1011/S42 Scatec-10
FLDM 170C1011/S42
FLDM 170G1030/S42 Scatec-15
FLDM 170C1030/S42
FLDM 170x10/xxxxxx customized
User manual
General notes
Rules for proper
usage
This product represents a precision measuring device which has been designed for
the detection of objects and parts. It generates and provides measured values
issued as electrical signals for following systems.
Unless this product has not been specifically marked it may not be used in
hazardous areas.
Set-up
Installation
Installation, mounting and adjustment of this product may only be executed by
skilled employees.
Only mounting devices and accessories specifically provided for this product may
be used for installation.
Unused outputs may not be connected. Unused strands of hard-wired sensors must
be isolated. Do not exceed the maximum permissible bending radius of the cable.
Before connecting the product electrically the system must be powered down.
Where screened cables are mandatory, they have to be used in order to assure EMI
protection. When assembling connectors and screened cables at customer site the
screen of the cable must be linked to the connector housing via a large contact
area.
User manual Scatec-10 / -15 2 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
Table of contents
1 Safety information
2 Certifications
3 Introduction
4 Principle of operation
5 Part identification
6 Terms and definitions
7 Signal sequence
8 Installation
9 Setting the operational parameters
10 Display and user menu
11 Specifications
12 Accessories
13 Maintenance
14 Troubleshooting
15 Varying data for customized FLDM 170x10/xxxxxx
16 Supplements
customized FLDM 170x10/xxxxxx: Data and information varying from the standard
manual are listed in section 15 !
User manual Scatec-10 / -15 3 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
1 Safety information
The laser diode installed in the Scatec-10 / -15 emits visible red light. This laser belongs to the Class 2 laser
standard specified by the IEC 60825-1 / 2007.
Avoid looking directly into the beam for long periods. Brief irradiation of the eye (0.25 sec) that can
occur during an accidental glance is not regarded to be dangerous.
However, the laser should not be aimed deliberately at people. The laser beam should also be blocked at the
end of its intended path.
2 Certifications
Scatec-10 / -15 complies with the following safety standards:
Complies with 21CFR 1040.10 and 1040.11
User manual Scatec-10 / -15 4 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
3 Introduction
As a member of the Scatec family, the Scatec-10 / -15 generally provides a means of detecting object
edges. These sensors are best suited for non-contact counting of overlapping paper sheets and newspapers
in the printing industry.
If an object with an edge facing the laser beam passes through the beam, the sensor reacts with an electrical
output pulse. The user has several options to set the Scatec-10 / -15 in such a way that certain edges are
recognized as “false edges” and consequently do not initiate an output pulse. This option of suppressing
certain edges allows the sensor to count newspapers to the highest degree of accuracy.
Within the Scatec family, the Scatec-10 and the Scatec-15 distinguish themselves by the following features:
Scatec-10 FLDM 170x1011/S42 Scatec-15 FLDM 170x1030/S42
• detects edges from a thickness of
0.1mm and thicker
• optimum working distance:
70 mm
• reliable gap detection via the built-in retroreflective sensor
(allowing consistent recognition of certain edges
as “false edges”)
• can be synchronized to the conveying speed
(allowing for enhanced false pulse suppression)
• high precision timing of pulse output
• counting rate up to 1.5 million copies per hour
• keypad and display for easy parameter setting
• detects edges from a thickness
of 0.1mm and thicker
• optimum working distance:
100 mm
• with interface for remote control and data
collection
(allowing analysis of product conditions while
production is running. Indispensable for test and
“trouble shooting”
User manual Scatec-10 / -15 5 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
• with CAN-interface for
remote control
4 Principle of operation
Described simply, the SCATEC-10 / -15 consists of a laser light source and two photo detectors. The beam
is aimed diagonally at the objects to be detected.
The photodetectors V and R detect laser light
scattered by an object in the forward and backward
direction, respectively. The ratio of light received by
these two detectors differs widely depending on
whether the beam strikes a flat surface or an edge.
Compared to a flat surface, an edge obstructs the
direct line of sight from the point of contact of the laser
to the detector V and hence detector V receives less
light. At the same time, an edge scatters more light
toward detector R than a flat surface. Both effects
cause the ratio of forward to backward scattered light
v/r to become substantially smaller than with a flat
surface. Therefore an edge is characterized by a value
of this ratio below a specific threshold.
This principle of operation clearly demonstrates that:
• The orientation of the object to the beam is
significant. An edge facing towards the beam
creates a small ratio v/r, in contrast to an edge
facing away from the beam.
• Edge detection is independent of the color, as only
the ratio of the light intensities and not the absolute
value is used for detection.
User manual Scatec-10 / -15 6 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
Frontwindow
Lower edge of
sensor
Display
Keypad
Main connector
Laser beam
5 Part identification
Edge-LED (amber)
Protection cap for
Interface connector
User manual Scatec-10 / -15 7 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
Line focus
(transverse to the Scatec)
6 Terms and definitions
Scatec-1x
h
k
Running direction
d
a
Conveying plane
Front edge
Beam blocker
Tail edge
Interfering edge
Mounting height h Distance between the lower edge of the sensor and the conveying plane.
Working distance d Distance between the lower edge of the sensor and the plane where the edge
lies on. Note that the working distance equals the mounting height only if the
edge lies directly on the conveying plane.
Overlap a Interval between two successive edges, measured along the conveying plane.
Edge thickness k Thickness of the copy at the point where the edge is to be detected.
Front edge The edge of an object which faces the laser beam. In principle, edges facing
the laser beam can be detected
by the Scatec, independently of
Laser beam
the running direction.
Tail edge The edge of an object which
faces away from the laser beam.
Edges facing away from the
laser beam cannot be detected
by the Scatec and do not initiate
Front edge:
detectable
Tail edge:
non-detectable
output pulses no matter the
running direction is.
Running direction For Scatec-10 / -15 both running
directions are allowed, with the
Laser beam
Running direction of copy:
front edge leading (a) or trailing
(b). A front edge is detected
(a) leading
independently of the running
direction. However, for certain
false pulse suppression modes to
(b) trailing
operate properly, the running
direction must be set correctly.
Interfering edge Folds, fissures, creases, or other imperfections on a newspaper can form
edges which will be detected by the Scatec but should not be counted. Such
edges are termed “interfering edges” and cause so called “false pulses”.
Scatec-10 / -15 offers several possibilities to efficiently suppress these false
pulses.
User manual Scatec-10 / -15 8 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
7 Signal sequence
The yellow edge indicator LED lights as long as the laser beam strikes an edge. The end of an edge (amber
edge LED turns off) triggers the output pulse and the dead time. The dead time starts immediately with the
trigger, while the delivery of the output pulse can be delayed (pulse delay adjustable by the customer).
During the dead time, SCATEC-10 /-15 is inactive, i.e. an edge ending during the dead time will not initiate
an output pulse and is therefore suppressed. As a consequence output pulses are separated in time by at
least the length of the dead time. Please note, the Scatec-10 / -15 cannot deliver the next pulse before the
preceding output pulse has elapsed. Therefore, an edge following after a time shorter than the output pulse
length will be suppressed, even when the dead time is set to zero. Suppressed edges do not trigger a dead
time.
The schematic below shows a pulse sequence where output pulses are delivered with no pulse delay and
where some edges are suppressed because they occur during a dead time.
For in-depth explanations of pulse length and dead time, please refer to section 9.2 Comments on the
operational parameters.
Running direction
on
off
high
low
on
off
time
amber edge-LED
p
t
output pulse (pulse period: p)
dead time (period: t )
User manual Scatec-10 / -15 9 / 44 Baumer Electric AG
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8 Installation
8.1 Electrical connection
Make the electrical connections as specified in Sections 11.2 Electrical data, 11.3 Pin assignment, and 11.6
Wiring instructions.
8.2
Mounting
(1) Scatec-10: Mount the sensor at a
mounting height h of 70 +/-2mm above
or below the conveying plane with the
front windows parallel (+/-3°) to the
conveying plane.
Scatec-15: Mount the sensor at a
mounting height h of 100 +/-2mm above
or below the conveying plane with the
front windows parallel (+/-3°) to the
conveying plane.
(2) Adjust the sensor so that the laser
beam is aimed towards the edges to be
counted. Note that the laser beam is
focused into a line which must be
aligned in parallel to the edges to be
detected!
(3) Block the laser beam after the objects
whenever possible.
(4) Keep the window clean (no fingerprints).
(5) A direct line of sight from the laser
impact point to the entire front window
must be ensured.
Comments:
Mounting height: h Scatec-10: 70 +/-2mm above or below the conveyor belt
Scatec-15: 100 +/-2mm above or below the conveyor belt
Scatec-1x
Scatec-15:
h=100 mm
Scatec-10:
h= 70 mm
1
Clean windows
Laser line focus
transverse to the Scatec
The resolution depends on the working distance. The highest resolution of 0.10 mm
edge thickness is achieved at a working distance d of 68 – 72 mm. (See also section
11.8 Application data)
The resolution depends on the working distance. The highest resolution of 0.15 mm
edge thickness is achieved at a working distance d of 97 – 103 mm. (See also
section 11.8 Application data)
4
5
2
3
Beam blocker
+/- 3°
1
Tilting tolerance max. +/- 3°
Overlap orientation The edges to be counted must face toward the laser beam (front edges) whether
they are leading or trailing.
Make sure, that the laser line is parallel to the edge to
be detected!
Scatec-1x
Front windows The direct line of sight from the impact point of the
laser to the entire front window must not be obstructed
by any hardware for potential laser impact points in a
distance range d of 0 – 150 mm (for Scatec-10) or 0 –
200 mm (for Scatec-15) If mounting brackets or other
components are close, consult a technician from
Baumer Electric.
Scatec-15: d=200 mm
Scatec-10: d=150 mm
d
User manual Scatec-10 / -15 10 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
8.3 Beam blocker
Uncontrolled reflections of the laser beam can cause malfunctioning of the sensor or disturb people.
Therefore, a beam blocker should be fitted whenever possible to block the beam when there is no target
present. A beam blocker is a flat surface (at least 25mm x 25mm) made of any matte non-reflecting material.
It is mounted parallel to the sensor at any convenient distance.
The amber edge-LED must not light while the laser beam hits a beam blocker!
8.4 Retro-reflective foil (Part # FTDF 025F025)
Gaps in a lap stream can be clearly detected by a Scatec-10 / -15 if the retro-reflective foil (part number
FTDF 025F025, shipped with the sensor) is mounted as a beam blocker.
Certain false pulse suppression modes are based on a clear gap detection (for detailed explanation of these
modes, refer to section 9.2 Comments on the operational parameters.)
Correct mounting of the retro-reflective foil:
1.) One side of the foil must be aligned parallel
to the laser line.
CORRECT FALSE
2.) Scatec-10:
Mounting distance: 70mm – 120mm away
from the sensor’s lower
edge.
Tilt: 10° - 60° relative to the
conveying plane
70 – 120 mm
Scatec-10
47°
Tilt :
10° - 60°
Retro-reflective foil
Conveying plane
Scatec-15:
Mounting distance: 100mm – 150mm away
Scatec-15
from the sensor’s lower
edge.
Tilt: 0° - 45° relative to the
conveying plane
100 – 150 mm
61°
Tilt :
0° - 45°
Retro-reflective foil
Conveying plane
The amber edge-LED must light while the laser beam hits the retro-reflective foil!
User manual Scatec-10 / -15 11 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
8.5 Cleaning the front windows
Fingerprints, dust and other forms of dirt on the front window can impair the function of the sensor. It is
normally sufficient to wipe the glass pane dry with a clean (!), soft cloth. Alcohol may be used for heavier
soiling.
9 Setting the operational parameters
Various parameters allow the customer to fully adjust the Scatec-10 / -15 to the specific demands of the
actual application.
Parameter adjusting can be done in the following ways:
• via a PC, an interface, and the application software ScaDiag (consult the ScaDiag-manual)
• via the CAN-interface (only for Scatec-15) (consult the Scatec CAN-manual)
• via the sensor’s key pad and display (described below)
Parameter setting via the sensor’s key pad and display
The setting of the operational parameters is done within a user’s menu, using the four key pads [set], [Esc],
[+], and [–].
The user’s menu and the navigation are described in detail in section 10 Display and user menu of this
manual.
The Scatec’s operational parameters are all grouped together in menu C.
This section of the manual describes in detail the characteristics of all the operational parameters. The
procedure of how to enter a specific parameter value by means of the key-pad is described in section 10
Display and user menu of this manual.
Note that usually the input has to be unlocked before any operational parameters can be changed.
The unlocking is done by setting setting parameter [B1] to off as follows:
1.) press [+] until B Locks is shown in the display
2.) press [set] : the display shows now B1: 1 = on Input lock
3.) press [set] : 1 = on is blinking
4.) press [+] until 0 = off is shown blinking in the display
5.) keep [set] pressed until blinking stops
Now the input is unlocked and the desired operational parameters can be set in menu C.
The input will be locked again if no key is pressed for 30 minutes.
User manual Scatec-10 / -15 12 / 44 Baumer Electric AG
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Flow chart for setting the operational parameters
C Parameters
C0 Pulse
Length [msec]
value
10.0
C3 Suppression
Mode
00 dynamic
01 synchronous
02 fixed
03 reflective
Operational
parameters are set !
C1 Running
Direction
0 = leading
1 = trailing
C2 False Pulse
C4 Dead Time
[%]
value
18
C8 Dead Time
[ms]
value
20
Suppression
0 = off
1 = on
C9 Pulse Delay
0 = off
1 = on
C10 Pulse Delay
[ms]
value
100
C15 Sensitivity Mode
0 = standard
1 = customized
C16 Sensitivity
01 high
02 medium
03 low
04 very low
C17 Threshold
C18 Hysteresis
C13 Tail Edge
Suppression
0 = standard
1 = extended
Setting
value
179
value
32
C14 Short Pulse
Suppression
0 = off
1 = on
Operational
parameters are set !
resolution [mm/pulse]
C6 Dead Path [mm]
FLDM 170G....
C7 Encoder A/B
0 = off (A only)
1 = on (A/B)
C5 Encoder
value
1
value
20
FLDM 170C....
C9 Pulse Delay
0 = off
1 = on
C11 Pulse Delay
[mm]
value
100
C12 Output at End
of Pulse Train
0 = first
1 = last
Default values are underlined. In most cases, the default setting will provide good results.
The factory preset default values can be reset anytime in submenu F4.
The names in the flow chart appear on the display as shown in square brackets in the next section.
User manual Scatec-10 / -15 13 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
r
9.1 Explanations on the operational parameters
Default values are either the underlined input values or the input value in [square brackets].
C0: Pulse Length [Pulse Length]
Input values: 0.3ms – 99.9ms in increments of 0.1ms [10ms]
Function: to set the duration of an output pulse
Comments: On the one hand, the duration of an output pulse must be long enough so that the
customer’s control system can process it. On the other hand, the length of the
output pulse limits the maximum counting rate. Because output pulses must not
overlap, the interval between edges must be at least as long as one output pulse
length. If the interval is shorter, then this edge will be suppressed meaning that the
edge will not initiate an output pulse.
The following figure illustrates how every other edge is suppressed because of a too
long of an output pulse length.
Scatec-1x
a
on
off
high
low
high
low
a
p
p
time
amber edge-LED
output pulse
pulse length p < interval a
output pulse
pulse length p > interval a
some edges are suppressed!
The maximum acceptable output pulse length for a given production rate can be
read from the diagram below.
Maximum acceptable output pulse length and
40
35
30
25
20
production rate
t
t: theoretical
r: recommended
15
10
5
maximum output pulse length [ms]
0
0.010 0.100 1.000 10.000
production rate [million copies / h]
User manual Scatec-10 / -15 14 / 44 Baumer Electric AG
Version 2011-03 www.baumer.com Frauenfeld, Switzerland
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