Prime Controls DS1522 Operating Instructions Manual
OPERATING INSTRUCTIONS
MODEL DS1522 DOUBLE SHEET DETECTOR
RIME
DS1522
DOUBLE SHEET DETECTOR
MESSAGES
Probe identification
Pr nn -
Selector switch position
SL nn -
Calibration Mode
CA -
flashing - Calibration fault
CE nn
flashing - Tx Probe fault
Pr 01
flashing - Rx Probe fault
Pr 02
flashing - Tx & Rx Probe fault
Pr 03
flashing - Fatal system fault
Er nn
PARAMETERS
(Press CAL button for 3 seconds)
Lower tolerance
Lt -
Upper tolerance
Ut -
Relay response delay
Ry -
Calibration trigger time
Ct -
Calibration delay time
Cd -
DISPLAY/SELECT
CALIBRATE GAP
CALIBRATE
P
CONTROLS, INC.
SIGNAL/MESSAGE
®
OVER
NOMINAL
UNDER
GAP
POWER OVER UNDER
100 - 240 AC OUTPUTS
AC
RELAY RELAY
AC
CONTROL I/O PROBES
INPUTS
CAL
RESET
COM
COM
AUXO
AUXIN
COM
COM
COM
FAULT
TMTR
TMTR
SHLD
RCVR
RCVR
SHLD
DESCRIPTION
The Model DS1522 Double Metal Sheet Detector comprises a control module in a sheet metal
housing with two probes to form a system that detects the thickness of metals passing between
the probes. The thickness is reported via two form C relays as “nominal”, “over”, “under” or
“nothing”. The DS1522 is capable of retaining up to 64 preset calibration setups which can be
invoked locally or remotely. This system may be used on automatic sheet feeders where
double or overlapped sheet material may jam or damage the receiving machine or ahead of roll
forming equipment to insure lap welds do not damage the equipment. A double feed or overlap
produces an output to stop the machine or signal the operator.
August 7, 2007
DESCRIPTION
System Features
The DS1522 is a highly flexible gauging system with a variety of features, some of which may
be enabled or disabled through the positioning of DIP switches located beneath the control
module cover. The various features include:
• Accommodates a family of probes allowing double detection on metals, from foil to heavy
plate.
• Manual calibration on single and double thickness for all metals.
• Manual calibration on single thickness for steel.
• Automatic calibration on steel after material absence for a preset trigger time.
• Automatic calibration after lap welds of steel coil stock (Firmware Version 2.21 and up).
• Automatic nominal adjustment for roll stock of varying thickness.
• Independent over and under tolerance adjustment in 1 percent increments.
• Optional multiple calibration presets (up to 64).
• Local or remote selection of preset memories.
Each of these features is described in greater detail later in this document.
Control Module
The features of the control module include:
• Universal power input accommodates AC voltages from 100 to 240 volts.
• Removable terminal blocks for quick change-out of the control module.
• Separate form C relay outputs for independent reporting of OVER and UNDER conditions.
• LED indicators report the current gage states of NOTHING, UNDER, NOMINAL, and
OVER.
• Automatic setup
of system gain and operating parameters.
• External or front panel calibration through a contact closure or the front panel push-button
switch.
• Sixty four calibration memories that are selected through the DISPLAY/SELECT pushbutton
or optionally through an external parallel connection to a PLC or selector switch. These
memories allow quick changeover between materials of different nominal thickness. The
memory contents are retained even when power is removed from the unit.
• Latching OVER and UNDER outputs that are cleared by asserting the RESET input.
• A fast, open collector logic output that is ON for nominal readings and OFF for OVER or
UNDER.
• An open collector FAULT output that may be connected to a master controller for
monitoring fault and gauge-not-active conditions.
• Probe fault reporting on the digital display warns of broken or disconnected probes or cables.
2
DESCRIPTION
Control Module Indicators
The function of the indicators and display on the DS1522 control module are described in the
following paragraphs:
1. OVER LED is ON whenever the material thickness exceeds the calibrated nominal value
by more than the set tolerance.
2. NOMINAL LED is ON whenever the received signal is within the specified tolerances,
both over and under.
3. UNDER LED is ON whenever there is material between the probes but the material thinner
than the calibrated nominal value by more than the set tolerance.
4. NOTHING LED is ON whenever the received signal goes beyond the measuring range of
the instrument indicating an absence of material between the probes.
5. The OVER, NOMINAL, UNDER, and NOTHING LEDs flash in succession when the
system is in calibrate mode.
6. Numeric Display indicates the level of the signal from the receiving probe and reports error
or status conditions. During gauge operation the value on the display reflects the strength
of the signal from the receiving probe. Thicker materials reduce the level of the signal
reaching the receiving probe, consequently the displayed value is lower for thicker material
and higher for thinner material.
Control Module DISPLAY/SELECT Pushbutton
Through the DISPLAY/SELECT pushbutton you can display the current local (Lc) preset
memory address if the DS1522 is off-line, i.e. the external enable signal is not asserted, or you
can display the current remote (rE) preset memory address if the GPIO signal is asserted. Thus
it is possible to determine if the unit is off-line or on-line by pressing the DISPLAY/SELECT
pushbutton and noting the identifier that displays. As long as the pushbutton is held, the
identifier displays. When the pushbutton is released, the currently selected preset address
displays for 5 seconds. The local address cannot be displayed if the DS1522 is on-line, i.e. the
external enable signal on the GPIO pin is asserted.
The local and remote addresses are independent values but they point to the same calibration
memories. When the external enable signal is asserted on the GPIO pin of the external select
port, the DS1522 is on-line and the remote address as applied to terminals IN1 through IN5 is
applied. The local address may not be displayed and changed while the DS1522 is on-line.
Conversely, the remote address may not be displayed while the DS1522 is off-line.
The local address can be changed by tapping the pushbutton while the value is displayed; the
remote address cannot. The remote address is determined by the signals entering the port at the
right of the control unit and cannot be changed locally. The local and remote addresses display
as a simple two digit number.
When the DISPLAY/SELECT pushbutton has been in the released state for 5 seconds, the
display reverts back to displaying gage information.
Control Module CALIBRATE GAP Pushbutton
The CALIBRATE GAP pushbutton initiates the gap calibration process. With no material
between the probes, press and hold the pushbutton for a minimum of three seconds to initiate
3
DESCRIPTION
gap calibration. The system responds by displaying alternately gAP and SU until the
calibration process is complete. Calibration of the gap needs to be done once whenever the
probes are changed or the physical spacing of the probes changes.
Control Module CALIBRATE Pushbutton
The CALIBRATE push-button switch on the front panel of the control module serves to initiate
the calibration process and to make adjustments to several numeric parameters including the
upper tolerance (Ut), the lower tolerance (Lt), the automatic calibration trigger time (Ct), the
calibration delay time (Cd), and the relay delays (ry).
To initiate calibration, simply press the pushbutton and release it within 3 seconds.
To view the current value of a parameter, press the pushbutton and hold it for more than 3
seconds until the appropriate parameter identifier appears on the digital display. After the
parameter identifier appears, release the pushbutton and the current value of the parameter
displays for 5 seconds. To retain the current value of the parameter, simply allow the 5 second
display interval to elapse. The display reverts back to displaying signal strength.
To change the value of a parameter, press the pushbutton and hold it for more than 3 seconds
until the appropriate parameter identifier appears on the digital display. After the parameter
identifier appears, release the pushbutton and the current value of the parameter displays. Press
the pushbutton while the parameter is displaying and the value increments, first slowly then
more rapidly. For more precise control of the value adjustment, simply tap the pushbutton
repeatedly until the desired value is displayed. All parameters roll back to their minimum
values after reaching the maximum value. To retain the adjusted value of the parameter,
simply allow the 5 second display interval to elapse. The display reverts back to displaying
signal strength.
4
DESCRIPTION
Control Module Configuration Switches
An eight position DIP switch is located beneath the front cover on the main control circuit
board to the left of the displays These switches must be set to enable the features of the system
that are appropriate to your application. Any time a switch setting is changed, the control
module must be powered down and back up to install the change. The switches are read only at
power up.
The functions of the switches are as follows:
Switch 1: OFF Disable automatic calibrate after double detection.
ON Enable automatic calibration after double detection (Version 2.1 and up)
Switch 2: OFF Automatic frequency selection during calibration.
ON Manual frequency selection (two-hit calibration only).
Switch 3: OFF Calibrate on single and double.
ON Calibrate on single only.
Switch 4: OFF Disable reference tracking.
ON Enable reference tracking.
Switch 5: OFF Slow memory changeover with address display
ON Rapid memory changeover, no address display (Version 1.7 and later)
Switch 6: OFF Disable automatic calibration trigger after material void.
ON Enable automatic calibration trigger after material void.
Switch 7: OFF Control interprets external selector port signals as high when activated.
ON Control interprets external selector port signals as low when activated.
Switch 8: OFF: The state of the relays for NOTHING in the gap is the same as for the
NOMINAL state.
ON: The state of the relays for NOTHING in the gap, is OVER for the OVER
relay and UNDER for the under relay.
Control Module Polarity Jumpers
Each of the logic inputs (CAL, RESET, and AUXIN) to the DS1522 has associated with it a
two position jumper plug located under the front cover and immediately behind its associated
connector. These jumpers allow the inputs to be driven by a sinking or sourcing 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, the input is set up
for a sinking driver, or dry contact between the input and COM.
Whether set for sinking or sourcing drivers, the input is active (ON) when the signal at the
terminal is low (at COM).
5
APPLICATION CONSIDERATIONS
APPLICATION CONSIDERATIONS
Choice of Probes
The DS1522 accommodates a number of Prime probes but is most often used with the P1000B,
P70A, and P70CS probes. The P70A and P1000B probes are potted and completely sealed
units with permanently attached cables. The P70CS probes are potted with connectors for easy
removal. The same probe type is used for transmitter and receiver and is not polarized.
The table below provides rule of thumb information for probe selection.
Probe Housing Connection Gap Application
P1000B Aluminum block Cable 0.5” to 1.25” 0.060 and thicker
P70A Threaded steel barrel Cable 0.5” to 0.75” 0.004 to 0.060 steel
P70CS Smooth stainless barrel Connector 0.5” to 3.00” 0.004 to 0.060 steel
Probes with non-ferrous (aluminum and stainless steel) housings offer greater probe separation.
Probes with steel housings are not affected by the material used for mounting. Probes with
aluminum or stainless steel housings are affected by steel near them including mounting clamps.
To realize maximum separation with the P70CS type units, the probes must be mounted in nonferrous clamps, e.g. Nylatron or 303 stainless steel.
Prime offers a number of other probes that allow the DS1522 to be applied to a wide range of
materials including magnesium, copper, stainless steel, and aluminum. For more information or
assistance in selecting the appropriate probes, contact Prime Controls.
Calibration Considerations
The DS1522 offers four different modes of calibration.
1. Manual calibration on single and double thickness material (two-hit calibration). In this
mode, a sample of the nominal thickness is placed between the probes and the CAL
pushbutton or optional external cal switch is pressed. Then a second thickness (or multiples
of the original) are placed between the probes and the CALIBRATE pushbutton or external
cal switch is again pressed. Calibration is complete unless the tolerance value must be
adjusted.
2. Manual calibration on single thickness steel (single-hit calibration). In this mode, calibration
can be initiated through a press of the CALIBRATE pushbutton or an optional external cal
switch prior to material entering the gap between the probes. The DS1522 enters a wait state
until material is fed between the probes. If the calibration delay parameter (Cd) is set to
zero, calibration occurs within 100 milliseconds after material is sensed between the probes.
For slow moving material, this delay can be increased (up to 9.9 seconds) to insure the
material fully covers the probes before calibration occurs. See the Control Module
CALIBRATE Pushbutton section earlier in this document for the parameter adjustment
procedure.
6
APPLICATION CONSIDERATIONS
3. Automatic calibration on single thickness steel after coil change (Switch 6 ON). In this
mode, calibration process is the same as for the manual single-hit calibration except that the
calibration process can be initiated by the expiration of a timer within the DS1522. The
timer can be set to a value from 0.1 minute (6 seconds) to 25 minutes. When the DS1522
detects the absence of material between the probes, the timer count-down begins. If the
count-down expires before material is sensed, the DS1522 enters calibration mode, waiting
for material to be fed. If the calibration delay parameter (Cd) is set to zero, calibration
occurs within 100 milliseconds after material is sensed between the probes. For slow moving
material, this delay can be increased (up to 9.9 seconds) to insure the material fully covers
the probes before calibration occurs. See the Control Module Calibrate Pushbutton
section earlier in this document for the parameter adjustment procedure.
4. Automatic calibration on single thickness steel after double (overlap) detected (Switch 1
ON). In this mode, available in systems with Firmware Version 2.1 and higher, the
calibration process is the same as for modes 2 and 3 above except that the calibration process
is initiated by the occurrence of a lap weld or overlap in the incoming material. When the
OVER condition is detected, the OVER relay switches for a minimum of 25 milliseconds and
then after the programmed calibration delay (Cd) calibration commences. The intent of this
mode is to detect lap joints and provide automatic recalibration on the material following the
lap joint.
When automatic calibration after double is enabled (Switch 1 ON), the calibration delay (Cd)
parameter may be used to insure calibration occurs beyond the overlap area. However,
should calibration occur on the overlap, the detection of an under condition after the overlap
will initiate recalibration if the under tolerance is set appropriately. The delay of relay
response through the “ry” parameter may still be used in this mode. However for detection
of short overlaps it may be necessary to set the relay delay to zero for fastest gauge response.
The choice of calibration mode is application dependent since each mode has its advantages and
disadvantages. Two-hit calibration offers the possibility of discriminating changes in metal
thickness that are far less than 2 to 1 since the system is calibrated on samples of the thickness
range to be discriminated.
Relay Response Time
For most applications it is desirable that the OVER relay respond as quickly as possible. For
thinner materials the response time is as fast as 3 milliseconds. For very thick metals the
response time can be as long as 40 milliseconds.
If very fast response times are undesirable, the action of the relays can be delayed through the
adjustment of the relay delay parameter (ry). This parameter represents a time interval in
fractions of a second from .00 to .99 seconds. To adjust the delay value, press and hold the CAL
pushbutton until the identifier “ry” appears on the two digit display. Release the pushbutton and
observe the current value of the delay parameter. Press and/or tap the CAL pushbutton as
necessary to bring the delay parameter to the desired value. To retain the adjusted value of the
parameter, simply allow the 5 second display interval to elapse. The display reverts back to
7
Loading...