Roland Double Sheet Detector R1000, I20-4-O-S, I20-2-O-S-FP, I20-4-O-S-FP, Double Sheet Detector I20 Series Series Manual

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DOUBLE SHEET CONTROL R1000 SERIES I20

Pos: 1 /Doppelblech/Geräte/I20/Deckblatt/Dec kblatt @ 1\mod_12018721 79421_501.doc @ 5733

Double Sheet Detector I20 R1000 series

Inductive principles – microcontroller based

Double sided non contact double sheet control of ferrous and non ferrous material

4 exchangeable linearized pairs of sensors for double sheet control of 0.15 – 10 mm (.004 - .255 inch) sheet thickness

4-channel version allows connection of up to four pairs of sensors

► Suitable for magnetic feeder systems

► Programmable for 255 different sheet thicknesses and materials

► Calibration by Teach-In procedure

► Digital display of sheet thickness and operational parameters

► Monitoring of over-gauge and under-gauge limit

► Monitoring of operating voltage sensor gap

► Galvanically isolated 10-bit input interface and 5-bit output interface

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2015 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.

===== Ende der Stückliste =====

Subject to change without further notice.

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Manual

Double Sheet Detector R1000 Series I20

B0069991 / Rev. 1.7

Table of contents

Declaration of conformity according to EC directives ..................................................................................... 5

1 Safety advices ........................................................................................................................................ 6

1.1 Safety instructions and warnings for user .......................................................................................... 6

1.2 Declaration of icons ............................................................................................................................ 7

1.3 Intended use ....................................................................................................................................... 7

2 Technical data ........................................................................................................................................ 9

2.1 Technical data control unit I20 ............................................................................................................ 9

2.2 Versions of the control unit I20 ......................................................................................................... 10

2.3 Sensors ............................................................................................................................................. 10

2.4 Dimensions of the sensors ............................................................................................................... 14

2.5 Sensor cables ................................................................................................................................... 15

2.6 Scope of delivery (accessories) ........................................................................................................ 16

3 System description .............................................................................................................................. 17

3.1 Measurement principle ..................................................................................................................... 17

3.2 System type ...................................................................................................................................... 17

3.3 General hints for process reliability .................................................................................................. 19

3.4 Control unit ....................................................................................................................................... 20

3.5 Parameters of the control unit .......................................................................................................... 20

3.6 Application examples ........................................................................................................................ 27

3.7 Tailor Welded Blanks ........................................................................................................................ 33

3.8 Design information regarding transporting velocity .......................................................................... 33

3.9 Secondary magnetic flux .................................................................................................................. 35

4 Mounting ............................................................................................................................................... 37

4.1 General mounting instructions .......................................................................................................... 37

4.2 Dimensions of the system ................................................................................................................ 38

4.3 Mounting of sensors ......................................................................................................................... 40

4.4 Sensor mounting in magnetic conveyors ......................................................................................... 44

5 Electrical installation ........................................................................................................................... 47

5.1 General instructions .......................................................................................................................... 47

5.2 Configuration of connectors .............................................................................................................. 47

5.3 Connecting diagram - examples ....................................................................................................... 50

6 Communication with the PLC ............................................................................................................. 55

6.1 PLC inputs ........................................................................................................................................ 55

6.2 PLC output signals ........................................................................................................................... 55

6.3 Timing diagrams ............................................................................................................................... 57

6.4 Internal control (Demo mode) ........................................................................................................... 68

7 Start-up .................................................................................................................................................. 69

7.1 Initially applying power to the system ............................................................................................... 69

7.2 Start screen ...................................................................................................................................... 69

7.3 Operation .......................................................................................................................................... 70

7.4 Configuration menu .......................................................................................................................... 71

7.5 General information regarding the configuration .............................................................................. 76

7.6 Changing, setting-up or checking the configuration ......................................................................... 76

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Manual

Double Sheet Detector R1000 Series I20

Table of contents

B0069991 / Rev. 1.7

7.7 Program parameters ........................................................................................................................ 78

7.8 Adjustment parameters .................................................................................................................... 87

7.9 System parameters .......................................................................................................................... 89

7.10 Data backup ..................................................................................................................................... 96

7.11 Firmware update .............................................................................................................................. 96

8 Operation ...............................................................................................................................................99

8.1 Abbreviated operating instructions .................................................................................................. 99

8.2 Entering a measurement program ................................................................................................. 100

8.3 Zero adjust (after sensor exchange) .............................................................................................. 101

8.4 Teach-In ......................................................................................................................................... 101

9 Fault messages, causes and remedies ........................................................................................... 103

9.1 Faults concerning memory ............................................................................................................ 104

9.2 Faults concerning USB data transmission (virtual RS232) ............................................................ 105

9.3 Faults concerning system operation .............................................................................................. 105

9.4 Faults concerning keyboard ........................................................................................................... 105

9.5 Faults concerning parallel interface ............................................................................................... 105

9.6 Faults concerning sensor test ........................................................................................................ 106

9.7 Faults concerning Teach-In / Zero adjust ...................................................................................... 106

9.8 Faults concerning sensors / sensor cables.................................................................................... 106

9.9 Faults concerning Hardware .......................................................................................................... 107

9.10 Faults concerning supply voltage .................................................................................................. 107

9.11 Other faults .................................................................................................................................... 107

10 Maintenance ....................................................................................................................................... 109

10.1 Replacement of sensors ................................................................................................................ 109

10.2 Exchange of control unit ................................................................................................................ 109

10.3 Replacement of fuses .................................................................................................................... 110

10.4 Data backup via USB interface ...................................................................................................... 110

10.5 Firmware update via USB interface ............................................................................................... 111

10.6 Spare parts .................................................................................................................................... 111

11 Technical records .............................................................................................................................. 113

11.1 Exchange of equipment ................................................................................................................. 113

12 Order data .......................................................................................................................................... 114

12.1 Versions of control unit I20 ............................................................................................................ 115

12.2 Sensors .......................................................................................................................................... 115

12.3 Cables ............................................................................................................................................ 115

12.4 Cable plugs and cable sockets ...................................................................................................... 116

12.5 Other accessories (within scope of delivery) ................................................................................. 116

13 Appendix ............................................................................................................................................ 117

13.1 System configuration form ............................................................................................................. 117

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

Declaration of conformity according to EC directives

Manufacturer: Roland Electronic GmbH

Otto-Maurer-Str. 17 DE 75210 Keltern

Product name:

Product type:

Roland Electronic GmbH declares that the product listed above complies with the requirements of the EMC directives listed below.

Applied Directives:

2006/95/EG Low Voltage Directive

EN61010-1: 2010

I20

Double Sheet Detector-series I20

Safety advices

2004/108/EG: EMC Directive

EN61000-6-2: 2005-08 EN61000-6-4: 2007-01

Date of mark’s apposition: 12.03.2015

Keltern, 12.03.2015

Place, Date Signature Function of the signer

Managing Director

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.

ISO 9001 : 2008

Reg.-no. 5152 QM08

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Manual

Double Sheet Detector-series I20

Safety advices B0069991 / Rev. 1.7

Blank page

1 Safety advices

1.1 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.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

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!

1.2 Declaration of icons

Warning - general dangers!

Reference to imminent hazards, which can result in severe bodily harm or death.

Warning - dangers by high voltage!

Reference to imminent hazards due to electricity, which can result in severe bodily harm or death.

Attention - Damage of construction units!

Reference to a potential imminent situation, which can result in damage to the product or environs.

Note

Useful reference to an application or deepening information.

Safety advices

1.3 Intended use

Flexible Manufacturing Systems in the sheet processing industry require reliable Double Sheet Control systems in order to protect presses and other sheet processing machines against damage caused by feeding multiple sheets.

The Double Sheet Detector R1000 I20 was specifically developed for this technical environment. Depending on the application (type of material, thickness, sensor gap) the I20 can be used with up to four pairs of sensors. The reliable function of the Double Sheet Detector depends therefore most importantly on the selection of the correct sensors and the mounting of the sensors.

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Manual

Double Sheet Detector-series I20

Technical data B0069991 / Rev. 1.7

Blank page

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

2 Technical data

2.1 Technical data control unit I20

Technical data control unit I20 Operating voltage: 24 VDC, +6 V / -4 V Power consumption: 15 W Switch on current: 10 A for 1 ms External fuse: 1 A medium time lag Ambient temperature: 0 - 50 °C (30 - 122° F)

Wall mount enclosure I20-2-O-S I20-4-O-S

Protection category: IP65 Dimensions, approx.. (W x H x D) mm 225 x 206 x 112 225 x 206 x 112 Dimensions, approx.. (W x H x D) inch 8.9 x 8.1 x 4.4 8.9 x 8.1 x 4.4 Weight, approx 4.0 kg (8.81 lbs) Valid from SN-No. 104358 delivery date 09/03/2009

Front panel enclosure I20-2-O-S-FP I20-4-O-S-FP

Protection category: IP40 (inside), IP65 (front cover) Dimensions, approx.. (W x H x D) mm 240 x 240 x 120 240 x 240 x 170 Dimensions, approx.. (W x H x D) inch 9.45 x 9.45 x 4.7 9.45 x 9.45 x 6.7 Weight, approx 2.2 kg (4.85 lbs) Additional characteristics: 255 parameter sets memory Programming via front panel keys

10 galvanically isolated optocoupler inputs 24 VDC with

common external supply

5 potential free outputs with positive external supply

Virtual RS232 interface (via USB) for data backup USB interface for Firmware update

Attention In order to protect the outputs from damage by inductive spikes, the

Specification:

- min. switching voltage HIGH: 13 VDC

- max. switching voltage HIGH: 30 VDC

- min. switching voltage LOW: 0 VDC

- max. switching voltage LOW: 8 VDC Specification:

- switching output: unwired Emitter and Collector

- max. switching voltage: 30 VDC

- max. switching current: 500 mA

outputs need to be protected by amply dimensioned flyback diodes.

Technical data

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Double Sheet Detector-series I20

Technical data B0069991 / Rev. 1.7

2.2 Versions of the control unit I20

The control unit article key ist coded as follows:

Control unit I20 with optocoupler interface

I20-2-O-S-FP

A B C D E

Based on the product key shown above, the following versions are available:

I20-2-O-S

I20-4-O-S Control unit for wall mounting, connection of up to 4 sensors,

I20-2-O-S-FP Control unit for front panel mounting, connection of up to 2 sensors,

I20-4-O-S-FP Control unit for front panel mounting, connection of up to 4 sensors,

Data backup

via serial USB

interface

Control unit for wall mounting, connection of up to 2 sensors, IN/OUT interface

IN/OUT interface

A Type of unit I20

B Number of sensors

C Outputs O Optocouplers

D Connection S pluggable

E Enclosure FP Front panel mounting

2 4 up to 2 sensors

up to 4 sensors

2.3 Sensors

The sensor description has the following code:

IS20-30GS

2.3.1 Sensor pair IS20-30GS / IE20-30GS

A B C D E

Technical data Application: Double sheet detection Sheet thickness:

0.05 – 4 mm for steel

0.05 – 10 mm for Aluminum (LW 20 – 30 MS/m):

0.2 – 10 mm for austenitic Stainless steel Sensor distance: see sensor diagrams Measurement principle: Eddy current Protection class: IP54 Weight: ca. 0.25 kg (0.55 lbs) Material of enclosure: Stainless steel / Brass, Nickel plated Sensor cable: Quick disconnect

A: Inductive sensor B: S = transmitter, E = receiver C: Diameter of sensor head D: Thread E: Quick disconnect

at nom. sensor distance (min. / max.) 20 (10 – 40) mm 20 (10 – 40) mm 20 (10 – 40) mm

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

2.3.2 Sensor pair IS42-30GS / IE42-30GS*

Technical data Application: Double sheet detection Sheet thickness:

0.15 – 8 mm for steel

0.1 – 10 mm for Aluminum (LW 20 – 30 MS/m):

0.4 – 10 mm for austenitic Stainless steel Sensor distance: see sensor diagrams Measurement principle: Eddy current Protection class: IP54 Weight: ca. 0.45 kg (1 lbs) Material of enclosure: Stainless steel / Brass, Nickel plated Sensor cable: Quick disconnect

* Transmitter ISQ42. and receiver IE42-30.. may be also used as a sensor pair. Please refer to chapter 4.3.1 for an example.

2.3.3 Sensor pair ISQ42S / IEQ42S* Sensor pair ISQ42FS / IEQ42FS*

Technical data Application: Double sheet detection Sheet thickness:

0.15 – 8 mm for steel

0.1 – 10 mm for Aluminum (LW 20 – 30 MS/m):

0.4 – 10 mm for austenitic Stainless steel Sensor distance: see sensor diagrams Measurement principle: Eddy current Protection class: IP54 Weight: ca. 0.50 kg (1.1 lbs) Material of enclosure: Plastic Sensor cable: ISQ / IEQ42S: Quick disconnect

ISQ / IEQ42FS: 0,2 m, cable firmly connected, with cable plug

* Transmitter ISQ42S and receiver IE42-30S, respectively transmitter IS42-30S and receiver IEQ42S may be also used as a sensor pair. Please refer to chapter 4.3.1 for an example.

Technical data

at nom. sensor distance (min. / max.) 40 (20 – 80) mm 40 (20 – 80) mm 40 (20 – 80) mm

2.3.4 Sensor pair ISQ160S / IEQ160S

Technical data Application: Sheet thickness: Depending on the application Sensor distance: 20 – 80 mm (depending on the application) Measurement principle: Eddy current Protection class: IP54 Weight: ca. 0.50 kg (1.1 lbs) Material of enclosure: Plastic Sensor cable: Quick disconnect

Part inspection, Material inspection, Hardness inspection

Note The stated measurement ranges are only valid for systems in „Standard“

setting. For details refer to chapter 3.2.

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Manual

Ax /

Double Sheet Detector-series I20

Technical data B0069991 / Rev. 1.7

2.3.5 Sensor diagrams

Sensor diagrams are available for determining the admissible measuring range depending on the gap between transmitter and receiver (Ax) and the material. Ax is specified as follows:

Fig. 1: Transmitter-receiver gap Ax

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 reliably detected, if the switching thresholds are set “tight”.

The working ranges of the sensors depend very much on the material properties, they can deviate from the sensor diagrams shown below.

Note The stated measurement ranges are only valid for units of type

„Standard“. For details refer to chapter 3.2.

Blech Shee

Ax diagrams for sensors IS / IE20-30GS

Ax (2 n)

Ax (n)

x (½ n)

Ax (2 n)

Ax (n)

x (½ n)

Ax (2 n)

Ax (n)

Ax / mm

0,05

Ax / mm

0,05

STEEL

234

Sheet thickness / mm

AL UMINUM

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

STAINLESS STEEL (Austenitic)

Ax(n) = nominal sensor gap

Sheet thickness / mm

x (½ n)

0,2

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Sheet thickness / mm

Fig. 2: Sensor diagrams for sensors IS / IE20-30GS

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Manual

)

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

Ax diagrams for sensors IS / IE42-30GS and ISQ / IEQ42S

Ax (2 n)

Ax ( n)

x (½ n

Ax (2 n)

Ax ( n)

x (½ n

Note The stated measurement ranges are only valid for systems in „Standard“

Ax / mm

STEEL

20,15 46 8

135 7

Technical data

setting. For details refer to chapter 3.2.

Ax(n) = nominal sensor gap

She et th ickn ess / mm

ALU MINU M

0,1

Ax ( 2 n)

Ax ( n)

x (½ n

Ax / mm

0,4

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

STAINL ESS ST EEL (Aus te n itic)

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Sheet thickness / m

Fig. 3: Sensor diagrams for sensors IS / IE42-30GS / ISQ / IEQ42S

Ax diagrams for sensors ISQ / IEQ160S

The sensors are specifically designed for Monitoring Parts for Hardened / Tempered Properties and Materials Mix up. The sensor gap can range from 20 to 80 mm depending on the geometry of the parts to be tested.

Note If more than 1 pair of sensors is connected to the system, the sensor

gaps may not deviate from each other more than ±10%. Otherwise the zero adjustment can be faulty.

Example: S1: 40 mm S2: 42 mm S3: 39 mm S4: 43 mm All values are within ±10%.

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Double Sheet Detector-series I20

Technical data B0069991 / Rev. 1.7

2.4 Dimensions of the sensors

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

Technical data

Fig. 4: Dimensions of IS/IE sensors bis SE75.wmf

2.5 Sensor cables

Cable marking:

The cables have quick disconnects at both ends. The plug at the control unit side is always straight.

SCI20S-GG with straight cable socket at the sensor SCI20S-GW with right angle cable socket at the sensor SCI20S-GG-TE extension cable for sensor cable (also use as quick disconnect)

Applicable to all cables:

Note The sensor cable is an active component of the sensor technology.

Bending radius: 50 mm at fixed installation

100 mm at flexible installation

Cable diameter: 7.1 mm

Suitable for drag chains, oil-proof, PUR jacket

Superflex Tronic(C)PUR TP 4 x 2 x 0.25 mm²

The technical data of the sensors is valid only if the cable specification is met. A shielded cable must be used. The cable length can be to up to 50 m. Following the rule "the shorter the better" generally leads to better measuring results.

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

Cable extension SCI20S-GG-TE

The cable extension SCI20S-GG-TE is inserted between the control unit and the existing regular sensor cable SCI20S-GG, SCI20S-GW.

Note: This cable must be used if the sensors ISQ/IEQ42FS (with firmly

connected cable) are taken.

2.5.1 Allocation of sensor cables SCI20S-GG, SCI20S-GW and SCI20S-GG-TE

Fig. 5: Allocation of sensor cables SCI20S-GG, SCI20S-GW and SCI20S-GG-TE

2.6 Scope of delivery (accessories)

Within the scope of delivery there are accessorial parts, which are separately packaged and put into the shipment box.

Fig. 6: Accessories, packaged

The volume of accessories depends on the version of the control unit. It is shown in Chapter 5.2 “Configuration of connectors“.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

3 System description

Flexible production systems in the sheet processing industry require automated, reliable double sheet detection in order to protect presses and other processing machinery from damage by multiple sheets. The I20 was specifically developed for this technical environment. The I20 is based on the product platform R1000 and consists in the standard version of three components:

• a control unit

• one pair of sensors (transmitter and receiver)

3.1 Measurement principle

3.2 System type

• one pair of sensor cables

The function of the sensor system is based on the measurement of eddy currents. The sensor system consists of a transmitter and a receiver.

The transmitter generates an electromagnetic field, which generates eddy currents in the target. The eddy current loss in the sheet dampens the electromagnetic field. These losses are measured in the receiver and are a measure of the sheet thickness (see also section ”Sensor diagrams“).

With the system parameter “System type“ the function of the I20 can be fundamentally changed. Possible choices are:

a) Standard

b) FE + AL 0.5 - 3 mm c) FE + AL 0.1 - 0,8 mm d) FE + Austenite 0.1 - 1 mm f) FE + Austenite 0.5 - 3 mm

g) Frequency

h) Damping mode

With the selections b) – f) the following applications are conceivable:

• Only 2 programs are used, one program for ferrous and the other one for nonferrous material. With each change of material the program for the corresponding material is switched and the first sheet is used for Teach-In.

• All programs are used. The Teach-In can be performed with running sheet, without stating nominal thickness and conductivity.

The selections b) - f) are intended as substitution for the mode “Dimension %“ known from the I10K.

System description

Here mm or inch can be selected as dimension. The nominal sheet thickness as well as the material must be entered. For NF (nonferrous) material the electrical conductivity must be entered,

or the conductivity must be determined at sheet standstill. Only then a dynamic Teach-In can be performed.

The materials which can be measured depend on the restrictions of the sensor pair used.

Restricted measurement range ! Here only % can be selected as dimension. The nominal sheet thickness does not need to (/cannot) be entered. Only FE (ferrous) and NF (nonferrous) material are available for

selection. A dynamic Teach-In can be directly performed. Depending on the selection (b - f) only those materials and thicknesses

can be measured! (restricted measurement range!)

Monitoring Parts for Hardened / Tempered Properties and Materials Mix up. The input of nominal dimensions is not necessary. The measurement frequency is adjusted according to the task under consideration (review the following explanations)

Within the system parameter „System type - Standard“ there will be no error-free dynamic Teach-In execution in a sophisticated constellation of work environment. The error message 151 "Sheet too thick" is reported. This problem occurs especially when using magnetic conveyors. For this case you must choose the system type “Damping mode“.

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

3.2.1 Explanation for System type “Frequency”

This adjustment of the I20 is used for applications to identify non-hardened or defective parts. The parts are passed through a sensor C-frame in which they are exposed to an eddy current field. Non-hardened or defective parts have a different field attenuation from good parts and can therefore be separated.

Roland Electronic supports the use with no charge application tests in order to ensure the feasibility of the project and obtain the optimum control unit adjustments.

Differences of the Adjustments of the I20 in Comparison to the Standard Use. Teach-In

• Instead of the single sheet (1-sheet) part A is used for a teach in of 100%

• Instead of two sheets (2 sheets) part B is used for a teach in of 200%

Sensors

• The pair of sensors ISQ160S/IEQS160S is primarily used for the system type "Frequency".

• Depending of the results of the application tests, the transmitter and the receiver are mounted in line either vertically (0°) or horizontally (90°).

Illustration with 0° and with 90°

Fig. 7: Illustration with 0° and 90°

Sensor Gap and Measuring Position

• The sensor gap must remain constant during the operating mode "Frequency". The sensor bracket must be correspondingly designed for this purpose.

• The measurement position of the part to be tested must be identical during Teach-In and measurement.

• For this application glass turntables are very well suited, magnetic transportation systems are not recommended.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

System description

Fig. 8: Glass turntable

Operation

• Instead of the nominal thickness the test frequency is selected for the adjustment of the program parameters. The type of material adjustment is not necessary. The optimum test frequency is determined at no charge in the application lab.

• The Teach in of 1 sheet and 2 sheet is substituted by the Teach-In of part A and part B respectively. Preferably a good part is being used being used for the Teach-In.

3.3 General hints for process reliability

The process security of the system is influenced by the following factors:

• the stability of the measuring values

• the setting of under-gauge threshold and over-gauge threshold

• the evaluation of the status signals

Stable measuring conditions will result in stable measuring results. Varying measuring results are undesirable, because in such cases the user is inclined to decrease the under-gauge threshold and to increase the over-gauge threshold. On doing so, the user puts up with the drastically increasing risk of not detecting a double sheet.

The following external factors decisively influence the stability of measuring results and need to be considered for operation of a double sheet detector:

• the magnetic characteristics of the material

• the tolerance in material thickness

• the geometric conditions at the place of measurement and at the sheet

• the pre-magnetization of FE material in case of magnetic transport systems.

• the smooth run of the material, with low vibrations

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

From this, some simple rules can be derived, to enable a high process security when abided by:

• Every different sheet (Thickness, material and contour) is measured with separate measuring program. For exceptions see chapter 3.6.

• The Teach-In has to be done with the same sheets (Thickness, material and contour) used when measuring.

• Adjust the switching thresholds as tight as possible!

• Keep the sensor gap constant!

• Ensure for sufficient covering of the measuring target!

• Keep the pre-magnetization of FE material as low as possible (suitable mounting of the transport magnets)!

• Pass the material guided through the sensor!

Furthermore it is necessary that the machine controls checks all status signals of the I20, also the 0-sheet signal. While measuring, only the 1-sheet signal may occur. If 0-sheet or 2-sheet occurs, the measured sheet may not be transported on. In such cases, the sheet will usually be removed.

• The machine controls needs to evaluate all status signals !

Checking-up through the 0-sheet signal is to assure that a sheet really is between the sensors during measuring. If 0-sheet occurs while measuring, the measurement is not correct. For example, a defective sensor holder might change the sensor gap. Monitoring the sheet thickness would then only be performed apparently.

In case of double sheet severe consequences could then result.

3.4 Control unit

The I20 is based on the product platform R1000. Major features of the control unit:

• Programmable for 255 different sheet thicknesses / types of sheets

• Calibration by a Teach-In procedure

• Digital display of sheet thickness and operating parameters

• Monitoring of over gauge and under gauge limits

• Monitoring of operating voltage and sensor gap

• Opto coupler for direct I/O control via the PLC for fast measurement operations

• Software firmware update

• Data backup via USB interface

3.5 Parameters of the control unit

The I20 provides for extensive configuration. So, different customer requirements can be served. Configuration is performed by setting system parameters and program parameters.

System parameters are set only once during commissioning, and will then remain unchanged. Program parameters contain items which are material and job depending, and enable individual

adaptation to the measuring task.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

3.5.1 Adjustment parameters

Adjustment parameters are assigned to the individual system. They apply only for this system and should not be transferred to another unit (control unit exchange).

“Zero adjust“

Before commissioning a new system, after having exchanged a sensor or a sensor cable or a control unit, a zero adjust must be performed. This zero adjust eliminates the variation of the sensors. The sensors will be zero adjusted “all in one stroke“.

• The zero adjustment is valid for all programs and should be performed only once !

“Test sensor distance”

Checks the sensor distances.

“Deviation of distance”

Indicates the deviation from the set sensor distances.

“Sensors distance”

Indicates the determined sensor distances in mm / inch.

“Control sensors”

Test of wiring / allocation of the sensors.

System description

3.5.2 System parameters

“Language“

System languages available for operating the unit via display and keyboard: German / English / Spanish / Italian / French.

“System type“

Fundamental setting of the system function. In „Standard“ setting the nominal thickness, the material and the electrical conductivity must be

specified. In the other settings (see chapter 3.2 system type b – f) this specification is not required, therefore only FE and NF material within the stated thickness range can be measured. For details refer to chapter 3.2.

The “Frequency” is specially designed for the Monitoring Parts for Hardened / Tempered Properties and Materials Mix up.

“Damping mode” is a special application. For details refer to chapter 3.2.

“Display value in…“

Switches the indication of the thickness values on the display between mm  inch.

“Display time”

Specifies the holding time for the screen display. Value range 0.0…2 seconds.

“CLR parameter (Clear Program Parameter)“

Deletes all program parameters. For doing so, the parameter needs to be set to “yes“. Executing the command requires several minutes, because the program memory will completely cleared. All program parameters will be reset to the default values and existing Teach-In data will be deleted. Using this function only makes sense if a unit is to be newly used for another machine.

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

“Password active“

Switches the password request on/off. If the password request is set “on“, the system / program parameters can only be changed after the password has been entered.

“Password”

Without password the system data are unprotected against unwanted change. Therefore a password should be set as soon as the installation is completed and regular operation has commenced. The factory preset password is “0000”, it can be set to a value between 0000 and

9999.

“Pairs of sensors“

Defines the number of connected sensors. Those sensors are then available for measuring. To a 2channel system I20-2 max. 2 sensors can be connected, at a 4-channel system I20-4 max. 4 sensors can be connected.

“Sensor type“

Currently the sensors IS/IE20-30S or IS/IE42-30S and ISQ/IEQ42FS or ISQ / IEQ160S are available. For those sensors characteristic curves for linearization purposes exists.

“Default settling time”

Defines the default time which the system requires to achieve stable measurement results, if the program parameter “settling time” is not available. For details refer to chapter 3.7.2.

“Measurement mode“

Sets how the measuring is to be triggered. The following modes are available:

• Ext. Single (default setting)

Here a single measuring is performed. For doing so, the signal “Measuring start“ must be externally applied. Another measuring requires a new flank of the “Measuring start“ signal.

• Demo

The demo mode is only intended for test and demonstration purposes. In this mode measuring is performed until the demo mode is switched off again. For doing so, another mode must be selected. The repetition time of the measuring is 4 ms.

• Ext. Permanently

Here the measuring is maintained as long as the signal “Measuring start“ is applied. The repetition time of the measuring is 4 ms.

• Ext. Special

As Ext. Permanently, but: the highest value measured during a measurement cycle is displayed and maintained until a new measurement cycle is started. This also applies for the 0-1-2-Warning outputs.

“Hold if 2-sheet“

Selection: “yes” or “no“.

• Yes: The outputs (0-sheet, 1-sheet and 2-sheet) are activated according to the number of

sheets between the sensors. If the equipment detects 2-sheet, the output 2-sheet is activated and the equipment is blocked until the 2-sheet condition is cleared, see Section “Mode of operation 2-sheet hold“.

• No: The outputs (0-sheet, 1-sheet and 2-sheet) are activated according to the number of

sheets between the sensors. The equipment does not block the operation if double sheet is encountered.

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B0069991 / Rev. 1.7

„Output level 0-1-2-warning“

Sets the output logic (0-sheet, 1-sheet, 2-sheet, warning) to 0V or +24V.

“Automat. prog. select”

Selects the method of program selection. If the program is switched frequently, “no” should be selected, otherwise the memory would be loaded with frequent writing cycles and its lifetime would decrease (1.000.000 writing cycles).

“IN / OUT PLC voltage”

Monitores the external PLC voltage. If “monitoring” is set and the PLC voltage is not connected, an error condition would be detected.

“External Adjust“

Determines whether an external Teach-In / zero adjust is to be possible. If “yes“ is set, the PLC can trigger the procedure via the inputs “Teach-In 0-, 1-sheet“. Default setting is “no“.

• The external adjust may only be performed under supervision of an operator.

“Internal analog zero”

Only for service personnel.

“Internal analog gain”

Only for service personnel.

“Diagnostic“

Diagnostics of the factors determined during the Teach-In. No default setting.

“Compensation factor”

Projected function.

“System info”

Displays the versions of Software and Hardware as well as the bus information. Identification of the control unit. These information needs to be at hand for telephone support.

System description

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Manual

Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

3.5.3 Program parameters

3.5.3.1 Program parameters for the Double sheet detection

This menu structure is valid for the system types a – f (for details refer to chapter 3.2) For measuring an eddy current method is used – called “Transmission” measurement. For

linearization purposes there are compensation curves, applicable to various conductivities and thicknesses. Magnetical materials have their own compensation curves.

To determine the compensation curves a calibration (later merely called “Teach-In“) must be performed.

In order to avoid frequent Teach-In procedures for different materials and thicknesses, the unit provides for 255 program memories. Every such memory consists of a data set with the relevant parameters.

“Program number”

Selects the number of the data set (1…255) which is to be applied for measurement.

“Sensor number“

Input of the selected sensor (/sensor sequence) for multi-channel systems (e.g. I20-4-…).

“Nominal thickness“

Specifies the nominal thickness of the sheets to be measured. Value range 0.000…15.00 mm (0.000…0.590 in) Default setting 0.00mm / 0.000 inch.

“Material”

Specifies the material to be measured. Choices: ferromagnetic material, non-magnetic material and non-magnetic material with unknown conductivity.

“Lower limit TL“ and “upper limit TU“

Changes the limit values for the lower and upper switching threshold. The values can be entered either in % or in mm/inch. On these thresholds depend the status signals.

In a window comparator the three signals will be generated from the measuring signal. The signal “0-sheet“ is generated when the measuring signal falls short of the lower switching threshold TL. The lower switching threshold TL can be set from 1...99%. The signal “2-sheet“ is generated when the upper switching threshold is exceeded. The upper switching threshold TU can be set from

100...180%. If the measuring value is within both limits, the signal “1-sheet“ is generated.

Obere Schaltschwelle

Upper switching threshold

Signal

Untere Schaltschwelle

Lower switching threshold

2 1 0

Fig. 9: Visualization of switching thresholds

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Signal range for 0-sheet Signal range for 1-sheet

Signal range for 2-sheet Upper switching threshold Lower switching threshold

a b

c TU TL

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B0069991 / Rev. 1.7

The preset values (TU=120% resp. TL=80%) should only be changed under the following aspects:

1. the 1-sheet range is permanently restricted, since the measuring values are very stable. Thus the process security increases. The restriction can be done by decreasing the TU value, by increasing the TL value, or both.

2. the 1-sheet range is temporarily extended. Thus the process security decreases. Such an action should only be performed in exceptional cases, the user has to decide about that. Extending the 1-sheet range is commonly considered due to mechanical problems (fluttering sheets). This measure prevents the machine from stoppages, until the mechanical problem is solved.

“Nom./curr. settling time”

Defines the time which the system requires to reach stable measurement results. For details refer to chapter 3.7.2.

“Teach-In 1-sheet“

The Teach-In calibration has to be executed with the material to be processed.

The calibration applies only to the selected program.

“Teach-In 2-sheet“

Because of the linearization of the sensor it is possible to measure with factory calibration in many applications, as long as thickness, conductivity and material type are known

For a more precise indication, the system can additionally be calibrated to a 2-sheet condition. The calibration applies only to the selected program.

System description

3.5.3.2 Program parameters for the Monitoring Parts for Hardened / Tempered Properties and Materials Mix up

This menu structure is valid for the system types g (for details refer to chapter 3.2) For measuring an eddy current method is used – called “Transmission” measurement. Compensation curves are being used for linearization. In order to avoid frequent Teach-In procedures for different materials and thicknesses, the unit provides for 255 program memories. Every such memory consists of a data set with the relevant parameters.

“Program number”

Selects the number of the data set (1…255) which is to be applied for measurement.

“Sensor number“

Input of the selected sensor (/sensor sequence) for multi-channel systems (e.g. I20-4-…).

“Frequency”

Adjustment of the measurement frequency for this measurement program.

“Lower limit TL“ and “upper limit TU“

Changes the limit values for the lower and upper switching threshold. The values can be entered in %. On these thresholds depend the status signals.

100...180%. If the measuring value is within both limits, the signal “1-sheet“ is generated.

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

Obere Schaltschwelle

Upper switching threshold

Signal

Untere Schaltschwelle

Lower switching threshold

Fig. 10: Visualization of switching thresholds

2 1 0

Signal range for 0-sheet Signal range for 1-sheet

Signal range for 2-sheet Upper switching threshold Lower switching threshold

a b

c TU TL

The switching thresholds should be adjusted corresponding to the application.

“Nom./curr. settling time”

Defines the time within the system must achieve a stable measurement result. For details refer to chapter 3.7.2.

“Teach-In Part A“

The unit calibrates part A to 100%. The calibration applies only to the currently selected program.

“Teach-In Part B“

The unit calibrates part B to 200%. The calibration applies only to the currently selected program.

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B0069991 / Rev. 1.7

3.6 Application examples

The following are two typical application examples for the use of the I20.

Kabel SCI20S Cable SCI20S

Kabelstecker 2277018 Cable plug 2277018

Kabel SCI20S Cable SCI20S

System description

Kabel SCI20S-GG-TE Cable SCI20S-GG-TE

Kabeldose 2276032

Cable socket 2276032

Kabelstecker 2277018

Cable plug 2277018

IS... IE...

Sender

IS...GS

Tran smi tter

ISQ...S

Kabel SCI20S-GG-TE (Verlängerung / Trennstelle) zwischen Gerät und Sensorkabel Cable SCI20S-GG-TE (extension / quick disconnect) between control unit and sensor cable

Empfänger Receiver

IE...GS IEQ...S

Kabeldose 2276032 Cable socket 2276032

Kabeldose 2276034 Cable socket 2276034

0,2 Meter

0.2 meters

ISQ...FS

Sender

Transmitter

0,2 Meter

0.2 meters

IEQ...FS

Empfänger

Receiver

For details on the extension cable SCI20S-GG-TE refer to 2.5.1

To the I20-2 up to 2 pairs of sensors of the same type can be directly connected, To the I20-4 up to 4 pairs of sensors.

The system is capable to measure:

a) sequentially by program switching in case of different sheet thickness, b) simultaneously in case of identical sheet thickness and if the thickness does not exceed a

ratio factor of 2:1 (sequencer).

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

Explanation of summary output 0-sheet, 1-sheet and 2-sheet:

If the unit is used in simultaneous mode (more than 1 sensor in a program e.g. 1+3+4), the measurement result is formed as summary output (via I/O and via the Fieldbus Byte 8-11). The priorities are:

2-sheet is issued if at least one sensor detects 2-sheet. 1-sheet is issued if all sensors detect 1-sheet. 0-sheet is issued if no 2-sheet is detected but at least one sensor detects 0-sheet.

Truth table for summary output

Sensor 1 Sensor 2 Sensor 3 Sensor 4

2-sheet is issued if:

2-sheet any condition

any condition 2-sheet any condition

1-sheet is issued if:

0-sheet is issued if:

1-sheet 1-sheet 1-sheet 1-sheet

0-sheet 0-sheet / 1-sheet

0-sheet / 1-sheet 0-sheet 0-sheet / 1-sheet

any condition 2-sheet

0-sheet / 1-sheet 0-sheet

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B0069991 / Rev. 1.7

Method a) sequentially by program switching

Meaningful, if the sheets to be monitored by the various sensors have different sheet thicknesses. Also suitable if the nominal thickness changes from cycle to cycle.

For this procedure the respective parameter set (program) must contain nominal thickness and sensor number. The selection of the program is then performed by the PLC.

The following is a typical application example

System description

Program Thickness Sensor

1 1,5 mm 1 2 0,7 mm 2 3 0,5 mm 3 4 0,8 mm 4

PLC

1. select Prog.1

2. measure Pr.1

3. evaluate result Pr.1

4. select Prog.2

5. measure Pr.2

6. evaluate result Pr.2

7. select Prog.3

8. measure Pr.3

9. evaluate result Pr.3

10. select Prog.4

11. measure Pr.4

12. evaluate result Pr.4

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

Method b) simultaneously (sequencer)

Advantageous when measuring the same sheet thickness with each sensor. Here the addressing of each sensor is done automatically by the I20. The inquiry of the sensors is predetermined in the program.

Note Advantage: Very fast measurements are possible, smaller software

effort on the PLC side.

Only one output is generated for connected sensors. The summary output is formed with the following priorities: 2-sheet before 0-sheet, 0-sheet before 1-sheet.

The following is a typical application example

Program Thickness Sensor

1 1,5 mm 1, 2, 3, 4

Start

PLC

1. measure Pr.1

2. evaluate result Pr.1

Note

The simultaneous measurement (sequencer) is also applicable for the simultaneous measurement of sheets with different thickness, with the following restrictions:

- the sheet thickness ratio must be less than 2:1

- each sheet thickness is controlled by a sensor pair

- the largest nominal sheet thickness is to be set. This will issued as measurement at each sensor pair as measured value

- for Teach-In it must be used at each sensor pair a sheet which later corresponds to the sheet thickness to be measured.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

System description

Program Thickness Sensor

1 1,0 mm 1, 2, 3, 4

1,5 mm 1,5 mm 0,6 mm 0,6 mm

PLC

1. measure Pr.1

2. evaluate result Pr.1

In addition to the selection by sensor number (see chapter 13 “System Configuration - number of sensors"), the following combinations of selections are available:

Combinations for 2 channel system Combinations for 4 channel system Sensor 1

Sensor 2 Sensor 1 + Sensor 2

Sensor 1 Sensor 2 Sensor 3 Sensor 4 Sensor 1 + Sensor 2 Sensor 1 + Sensor 3 Sensor 1 + Sensor 4 Sensor 2 + Sensor 3 Sensor 2 + Sensor 4 Sensor 3 + Sensor 4 Sensor 1 + Sensor 2 + Sensor 3 Sensor 1 + Sensor 2 + Sensor 4 Sensor 1 + Sensor 3 + Sensor 4 Sensor 2 + Sensor 3 + Sensor 4 Sensor 1 + Sensor 2 + Sensor 3 + Sensor 4

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

Note If all four pairs of sensors are activated (system parameter “pairs of

sensors”, each possible combination with only 2 or 3 sensors can be selected. On the other hand the combinations for example for the sensor number 4 cannot be selected, if only 3 sensors are activated.

The following rule applies: The highest sensor number in the combination

determines the minimum number of activated sensors.

Note The combination is a program parameter, therefore methods a) and b) can

form a practical combination, for example, two stacks of sheets for instance left and right blanks with different thicknesses can thus be checked for double sheet.

The following is a typical application example

Program Thickness Sensor

1 1,5 mm 1, 2 2 1,8 mm 3, 4

Start

PLC

1. select Prog.1

2. measure Pr.1

3. evaluate result Pr.1

4. select Prog.2

5. measure Pr.2

6. evaluate result Pr.2

1,5 mm 1,5 mm 1,8 mm 1,8 m

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

3.7 Tailor Welded Blanks

While processing tailor welded blanks (sheet consists of two or more thicknesses), the nominal thickness of the thickest sheet will be chosen to be entered.

System description

D2 D1

I20-...

Program Parameter: Lower threshold 80% mm

Higher threshold 120% mm

3.8 Design information regarding transporting velocity

3.8.1 Sensor coverage / Measurement target

For details refer to chapter 4.3.2 “Measurement target”

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Double Sheet Detector-series I20

System description B0069991 / Rev. 1.7

3.8.2 Settling time ts and measuring time tm

Settling time ts

The settling time t

Zustand “Blech”

Condition “sheet”

Sensorsignal

Sensor signal

Fig. 11: Illustration of settling time

The settling time ts is shown in program parameter 7 as actual / target settling time. Possible values for the settling time: 2ms, 4ms, 8ms, 15ms, 25ms, 100ms, 250ms. If the achieved

settling time exceeds the desired value, the system selects the next possible higher value. For details see Chapter 7 „Start-up“, „Program parameter 7“.

Material Thickness range Minimal settling time Damping mode

FE 6 – 8 mm

Aluminum

(LW 20)

Explanation: For non ferrous material: the thicker the sheet is, the longer the settling time, the larger the electrical conductivity, the longer the settling time.

is the time required by the system to produce stable measurement results.

3,5 – 6 mm

2,5 – 3,5 / 4 mm

1,6 – 2,5 mm 1,2 – 1,6 mm 0,8 – 1,2 mm

< 0,8 mm

6,6 – 12 mm 3,3 – 6,6 mm 1,6 – 3,3 mm

< 1,6 mm

Note General: A longer settling time t

250 ms (only for sensor 42-30) 100 ms (only for sensor 42-30)

25 ms 15 ms

8 ms 4 ms 2 ms

15 ms

8 ms 4 ms 2 ms

will result in more precise

250 ms (only for sensor 42-30) 100 ms (only for sensor 42-30)

25 ms

25ms 15ms

0.5 - 1,2mm 8ms < 0.5mm 4ms

15 ms

8 ms 4 ms 2 ms

measurement results, due to the averaging effect. The setting of the settling time influences the max. transport velocity of

sheets.

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B0069991 / Rev. 1.7

System description

Measurement time tm

The measurement time t

is the entire time, which the system requires from „Measurement Start“

to delivering of the output signal.

Messung Start

Measurement Start

Ausgangssignal

Output signal

Fig. 12: Illustration of measurement time

Operation by I/O inputs have a constant measurement time tm of 4 ms. In case of reading out the measurement result via Fieldbus an extra time of 4 ms is required.

3.8.3 Maximum permissible transportation during double sheet control

The maximum permissible transportation speed of the metal blank depends on the sheet length, the measurement target and the settling time t

With a upper threshold TU = 130% (see program parameters) the following guide lines apply:

Max. permissible transport speed [m/s] <

with sensor gap < sensor diameter.

Sheet length [mm] – 3× Sensor diameter [mm]

ts [ms] + 2 [ms]

3.8.4 Measurement at standstill of sheet

For measuring of sheets in standstill condition, the following must be considered:

• The covering of the sensors must be 3 times the sensor diameter.

• The necessary minimum residence time is as long as settling time plus measurement time

3.9 Secondary magnetic flux

Magnetic conveyors can generate a secondary magnetic flux in the transported sheet which can distort the measured value. The influence of the secondary magnetic flux can the minimized by mounting the sensors away from the magnets as much as possible and also mounting the magnets in such a way as to reduce secondary magnetic flux. For details refer to chapter 4.4.

By using the “dynamic Teach-In” function, the system considers this influence.

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B0069991 / Rev. 1.7

Blank page

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

4 Mounting

The mounting of the Double Sheet Detector R1000 I20 determines the measurement accuracy and the reliability of operation. The system was designed for operating in rough industrial environments. However, the following mounting instructions should be observed in order to minimize mechanical, thermal, and electromagnetic influences on the operation.

4.1 General mounting instructions

The enclosure for wall mounting meets IP65 and is designed for mounting the enclosure close to the sensor location. This results in the use of shorter sensor cables with a corresponding lower exposure to electromagnetic noise and could therefore result in better measurements.

The control unit should be installed in locations where no vibration exists and no additional heat is transferred into the system (even better reduce the heat in the control unit). In addition the control unit should be installed in such a fashion that it can be easily opened for service purposes. During the operation the control unit and the sensors should be under visual control of the operating personnel.

Attention Strong vibrations and additional heat can damage the control unit.

Mounting

In case of panels or operator consoles the front panel version may be used.

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Mounting B0069991 / Rev. 1.7

4.2 Dimensions of the system

4.2.1 Unit in industrial enclosure

2-channel unit I20-2-O-S / 4-channel unit I20-4-O-S

I20-2-O-S

I20-4-O-S

All dimensions are in mm. Tolerance ±0,4 mm

Fig. 13: Dimensions of the 2-channel / 4-channel unit in wall mount enclosure

Note A minimum depth of 120 mm is required for connecting the plugs.

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

4.2.2 Front panel enclosure

I20-2-O-S-FP / I20-4-O-S-FP

220240

Mounting

Front plate cutout 194 x 194 mm

220 240

All dimensions are in mm. Tolerance: ±0.4 mm

Fig. 14: Dimensions of the front panel enclosure -front view

4 x Ø 4,2 for Philips head screw M4 DIN 74

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Manual

Double Sheet Detector-series I20

Mounting B0069991 / Rev. 1.7

Fig. 15: Dimensions of the front panel enclosure - side view

Note: A minimum depth of 120 mm is required for connecting the plugs

(see figure on next page).

4.3 Mounting of sensors

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All dimensions are in mm. Tolerance: ±0.4 mm

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

The reliable function of the Double Sheet Detector depends to a great degree on the correct mounting of the sensors. The following mounting rules should be followed:

The sensor pair can be mounted in any direction. Transmitter and receiver must be installed aligned opposite to each other. The use of a short C-frame is ideal. It provides a good stability and guarantees a constant distance between transmitter and receiver.

On the rear side the sensors have a mounting thread M30 × 1.5 mm for mounting at holders of all materials. If the sensors cannot be mounted by means of the mounting thread, they can be fixed by clamping at the front sleeve, but only by clamp holders made of plastic material.

Fig. 16: External shields to protect the sensor from transferred sheets

Attention If the sensors are mounted by clamping at the front sleeve, no metallic

During the measurement no moving metallic parts should be present within a radius of 80 mm of the sensor center.

Mounting

If the sensors are mounted protruding, care must be taken that the running coil cannot damage the sensors. If necessary, the sensors must be protected with additional shields (×) from damage by incoming sheets.

Recessed mounting of the sensors must be avoided, because dirt and shavings can accumulate on the sensor surfaces and result in reduced measurement security.

The illustration also shows a design recommendation for a sensor holder.

holder may be used, because the sensor performance can be considerably reduced.

80 mm

The mounting position must be selected, so that the sensors can be easily changed. Care must be taken that the once set sensor gap can be easily reproduced in case of sensor change. Only then a renewed Teach-In of all parameter sets can be avoided.

4.3.1 Possible combinations of transmitter and receiver

It is possible to use following types of transmitter and receiver together:

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Manual

Double Sheet Detector-series I20

Mounting B0069991 / Rev. 1.7

Fig. 17: Example of sensor holding with combinations of sensors IE42-30S and ISQ42S

4.3.2 Measurement target

This description is not for the operating mode “Frequency” (Monitoring Parts for Hardened / Tempered Properties and Materials Mix up)

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).

Sensor type IS42-30GS / IE42-30GS or ISQ42S / IEQ42S

Sensor gap

Minimal distance to the sheet edge

“X”

20 mm 36 mm 114 mm

40 mm 42 mm 126 mm

70 mm 63 mm 168 mm

80 mm 73,5 mm 189 mm

Sensor type IS20-30GS / IE20-30GS

Sensor gap

Minimal distance to the sheet edge

“X”

20 mm 31 mm 82 mm

40 mm 38 mm 96 mm

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.

Minimal measurement target diameter

“D”

Minimal measurement target diameter

“D”

Fig. 18: Measurement target

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

4.3.3 Position of the sheet in the sensor gap

Ideally the sheet should be transferred through the middle of the sensor gap. This guarantees reliable and accurate results of the measurement. The sheet to be measured must be in the same position in the sensor gap during Teach-In and during the normal operation. If the position of the sheet changes during normal operation from the Teach-In position then the measured value changes also. The larger the deviation of the measurement position the larger is the distortion of the measured value.

4.3.4 Sensor distances

The usable sensor distances can be read from the sensor diagrams.

Note If more than 1 sensor pair is connected to the system, the sensor

distances may not deviate from each other for more than ±10%. Otherwise the zero adjustment can be faulty.

Example: S1: 40mm S2: 42mm S3: 39mm S4: 43mm All values are within ±10%.

For details refer to chapter 2.3

Mounting

4.3.5 Distance between adjacent pairs of sensors

In order to except adjacent sensor pairs from influencing each other, a distance of the sensor pairs of min. 120 mm (between the center axis of the sensors) must be kept.

4.3.6 Electromagnetic interference

Electromagnetic interference can affect the measuring accuracy of the sensor. Therefore the sensors should not be installed close to devices which cause electromagnetic interference. Such devices are e.g. frequency converters, servo motors or proximity switches on inductive basis.

In case of switching magnets a minimum distance of 30 mm should be respected in order to

avoid feedback. For proximity switches a minimum distance of 120 mm is required. The sensor cables should not be placed directly adjacent to cables with large interference potential,

e.g. power supply cable. This applies especially to longer cable lengths.

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Manual

y f

Double Sheet Detector-series I20

Mounting B0069991 / Rev. 1.7

4.4 Sensor mounting in magnetic conveyors

Note If the sheets are transported with magnetic conveyors, then the receiver

sensor should be mounted on the side that is opposite to the magnets.

If electromagnets are used in the conveyor belts, they must be supplied

with DC current. The residual ripple of the supply voltage must not exceed 5%. The supply voltage / current of the electromagnets may not be pulsed during the measurement, as this distorts the measurement result.

The mounting of the sensors according to the following picture results in reliable double sheet detection. It is important that the holding magnets are arranged in such a way that no secondary magnetic flux develops between two magnetic conveyors rails either through the air or the sheet. It is important that the mounting of the magnets in the conveyor belts results in an opposite magnetic flux configuration of the type N<-->N or S<-->S.

No secondar

Conveyor rails Conveyor rails

lux

Ay Ay

Primary

flux

Ax: see sensor diagram

for the sensor

Sensor Transmitter

10 mm

40...60(70) mm

Sensor

Receiver

Use plastic brackets with a cap of about 3 mm to prevent bended sheets from damaging the sensor

Primary flux

Ay: > 30 mm

10 mm

40...60(70) mm

Fig. 19: Sensor mounting, lateral view

Whenever possible the sensors should not be mounted close to the magnetic rails, but with the greatest possible distance between the conveyors rails. The mounting brackets should consist of plastic or stainless steel. Aluminum or materials of high electrical conductivity dampen the sensors and reduce the performance substantially.

 In order to reduce the disturbing effect of the magnets in dynamic measuring mode, we suggest

to mount the receiver at the largest possible distance. As a minimum distance for sensor type IE42-30GS we require 40 mm.

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

N S

Fig. 20: Sensor mounting, top view (*Sensor)

> 50 cm

S N

Mounting

S N

Note The sensors should be mounted wherever possible 50 cm after the

N S

start of the magnetic tape drive.

Note If electromagnets are used in the conveyor belts, the

electromagnets must be supplied with DC voltage / current. The residual ripple of the supply voltage must not exceed 5%. The supply voltage or the supply current of the electromagnets is not be clocked during the measurement, as this can affect the measurement result.

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Manual

Double Sheet Detector-series I20

Electrical installation B0069991 / Rev. 1.7

Blank page

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Page 47

Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

5 Electrical installation

5.1 General instructions

The sensor cables should be kept as short as possible in order to minimize the influence of electromagnetic noise. Cable shields must be connected according to the connection diagrams only and should not have any additional connections.

Attention Damaged cable installations can result in additional electrical

connections. This can disturb the measured values.

5.2 Configuration of connectors

5.2.1 Configuration of connectors at the I20-2-O-S / I20-4-O-S

(to connect up to 2 / 4 sensor pairs)

Legend

A Central connector B Grounding screw bolt

S1 Socket f. sensor transmitter 1 E1 Socket f. sensor receiver 1 S2 Socket f. sensor transmitter 2

S1S2S3S4

E2 Socket f. sensor receiver 2 S3 Socket f. sensor transmitter 3 E3 Socket f. sensor receiver 3 S4 Socket f. sensor transmitter 4 E4 Socket f. sensor receiver 4

The USB terminals are at the front plate.

Electrical installation

E3E4

Fig. 21: Connections on 2-channel unit / 4-channel unit

E1E

In case of I20-2-O-S the connections S3, E3, S4 and E4 are omitted.

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Manual

Double Sheet Detector-series I20

Electrical installation B0069991 / Rev. 1.7

5.2.2 Central connector (connection A)

At the central plug the supply voltage as well as the inputs and outputs of the PLC are connected.

View of connection side

Fig. 22: Central connector

5.2.3 Wiring diagram

PLC

grounding

point

External power supply

Central machine grounding

Measurement start

Program switching

Teach-in 1-sheet

Teach-in range

Zero adjust

Clear 2-sheet / 0-1-2-wa outputs

System test (gap control)

Data OUT

Teach-in 2-sheet

Material detection NF

Reset fault

PLC / COM

+24 VDC / PLC

ENABLE

2-sheet

1-sheet

Data IN

0-sheet

Warn ing

+ 24 VDC

0 VDC

LiYCY 18 x min. 0.25 mm

min. 0.5 mm

min. 1.5 mm

Central plug

Bit 0

Bit 1

Bit 2

Bit 3

Bit 4

Bit 5

Bit 6

Bit 7

IN1

IN2

IN3

IN4

IN5

IN6

IN7

IN8

PLC / COM f. IN and OUT

PLC + 24 VDC f. IN and OUT

OUT0 Enable

OUT1 2-sheet

OUT2 1-sheet

OUT3 0-sheet

OUT4 Warning

+24 VDC

0 VDC

IN0

IN9

I20

Fig. 23: Diagram of wiring between PLC and I20 control unit

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

5.2.4 Pin configuration of control unit – opto coupler outputs

Data inputs PLC – Central plug at I20

PLC Central plug

Function Pin no. Input Specification

Measurement start B 7 IN 0

Measuring menu

selection = 0

Teach-In 1-sheet Bit 0 A 2 IN 2

Teach-In range Bit 1 A 3 IN 3

Zero adjust Bit 2 A 4 IN 4

Confirm 2-sheet (CLR outputs) Bit 3 A 5 IN 5

System test (gap control) Bit 4 A 6 IN 6

Teach-In 2-sheet Bit 5 A 7 IN 7

Material detection NF Bit 6 A 8 IN 8

Reset fault Bit 7 B 8 IN 9

PLC / COM A 9 Common 0V DC for IN and OUT

Data outputs PLC – Central plug at I20

PLC Central plug

Function Pin no. Outputs Specification

+24 VDC voltage supply for opto couplers from PLC interface C 1

Output is HIGH if ENABLE is active (unit o.k.) C 2 OUT 0

Output is LOW if 2-sheet is detected C 4 OUT 1 Output is LOW if 1-sheet is detected C 6 OUT 2 Output is LOW if 0-sheet is detected C 8 OUT 3

Output is LOW if Warning is detected C 9 OUT 4

Output current: absolute max. 500 mA / continuous max. 300 mA

Supply voltage External power supply – Central plug at I20

External power supply Central plug

Voltage Pin no. Specification 24 VDC B2 24 VDC +6 V / –4 V / min. 0.5 mm2

0 VDC B3 min. 0.5 mm2

Central machine grounding Grounding min. 1,5 mm2

Measuring menu

selection = 1

A 1 IN 1

+24 VDC ± 4 VDC

Electrical installation

Sinking

input

LOW: 0-8V,

HIGH: 13-30V

for IN and OUT

Sourcing

output

5.2.5 Connection of machine earth ground (connection B)

For earth ground connection, the enclosure of the R1000 has an M6 threaded screw. Here the grounding cable (copper) of at least 1.5 mm² cross section must be connected to the earth ground of the machine. The connection is obligatory!

Attention The positive supply voltage +24 VDC should not be connected to machine ground.

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Manual

Double Sheet Detector-series I20

Electrical installation B0069991 / Rev. 1.7

5.2.6 Voltage supply

The supply cable for the voltage supply should be kept as short as possible. For cable lengths up to 20 m the cable should have 2×0.5 mm be accordingly increased. For power consumption of the system please refer to section “technical data”.

Attention The positive supply voltage +24 VDC should not be connected to machine ground.

, for larger lengths the cross section of the cable needs to

5.2.7 Sensor connection (connections S1–4 and E1–4)

The sensor cable SCI20-S is connected at the control unit by plug. Because of the special wiring of the sensor cable SCI20S it is no longer necessary to avoid mixing

transmitter and receiver cable. When using the SCI20S cable the transmitting sensor and the receiving sensor will automatically be connected to the appropriate sockets of the control unit.

Note The sensor cable is an active part of the sensor. The performance

data is therefore based on the compliance with cable specification.

Allocation of sensor connections

Connector at control unit (pos. S1-4, E1-4)

View: Plug side

Suppliers / types / notes: ODU, Mini-Snap, Series K

5.3 Connecting diagram - examples

All sensor pairs are connected in the same manner. Because of the special wiring of the sensor cable SCI20S it is no longer necessary to avoid mixing

transmitter and receiver cable. When using the SCI20S cable the transmitting sensor and the receiving sensor will automatically be connected to the appropriate sockets of the control unit.

Socket insert 7-pin, size 2

Pin 1 +8V

Pin 2 -8V

Pin 3 GND

Pin 4 Transmitter 1

Pin 5 Transmitter 2

Pin 6 Receiver 1

Pin 7 Receiver 2

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

5.3.1 Connecting diagram I20-2 with one sensor pair

Kabelstecker 2277018 Cable plug 227701 8

Electrical installation

Kabel SCI20S

Cable SCI20S

Empfänger Receiver

IE...GS IEQ...S

Kabeldose 2276032 Cable socket 2276032

Kabeldose 2276032

Cable socket 2276032

Fig. 24: I20 with one sensor pair

Kabel SCI20S Cable SCI20S

IS...GS ISQ...S

Transmitter

IS... IE...

Sender

Cable extension SCI20S-GG-TE

The cable extension SCI20S-GG-TE is inserted between the control unit and the existing regular sensor cable SCI20S-GG / SCI20S-GW.

Note If the sensors ISQ/IEQ42FS (with firmly attached cable) are used,

this cable must be used for extending the sensor cable.

For details refer to chapter 2.5.1.

Kabelstecker 2277018

Cable plug 2277018

Kabel SCI20S-GG-TE (Verlängerung / Trennstelle) zwischen Gerät und Sensorkabel Cable SCI20S-GG-TE (extension / quick disconnect) between control unit and sensor cable

Fig. 25: Cable extension SCI20S-GG-TE

Kabeldose 2276034 Cable socket 2276034

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Manual

Double Sheet Detector-series I20

Electrical installation B0069991 / Rev. 1.7

0,2 Meter

Kabel SCI20SCable SCI20S-

0,2 Meter

0.2 meters

Kabel SCI20S-GG-TE Cable SCI20S-GG-TE

Kabel SCI20S Cable SCI20S

Kabel SCI20S-GG-TE Cable SCI20S-GG-TE

Kabelstecker 2277018 Cable plug 2277018

Kabel SCI20S

Cable SCI20S

Kabel SCI20S-GG-TE Cable SCI20S-GG-TE

0.2 meters

Kabeldose 2276032

Cable socket 2276032

IS...GS ISQ...S

Fig. 26: I20 with one sensor pair and cable extension SCI20S-GG-TE

IS... IE...

Sender

Transmitter

Empfänger Receiver

Kabeldose 2276032

Cable socket 2276032 IE...GS IEQ...S

ISQ...FS

Sender

Transmitter

IEQ...FS Empfänger Receiver

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

5.3.2 Connecting diagram I20-4 with four sensor pairs

1234

Electrical installation

Fig. 27: I20-4 with four sensor pairs

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

Blank page

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

6 Communication with the PLC

The I20 has 10 galvanically isolated (opto coupled) inputs and 5 galvanically isolated (opto coupled) outputs.

6.1 PLC inputs

If different functions are performed at the same time, an fault message will be generated. The following functions are possible:

1. Measurement Start / Stop

2. System test (gap control sensors)

3. Program switching

4. Clear 2-sheet / Clear 0-1-2-wa outputs

5. Zero adjust (not active by default)

6. Material detection NF (with first selected sensor)

7. Teach-In 1-sheet (not active by default)

8. Teach-In 2-sheet (not active by default)

9. Reset Fault

Communication with the PLC

6.2 PLC output signals

The following signals are available as outputs:

Signal Meaning Note

OUT3 0-sheet output Standard 0 V active (selectable in system configuration)

OUT2 1-sheet output Standard 0 V active (selectable in system configuration)

OUT1 2-sheet output Standard 0 V active (selectable in system configuration)

OUT0 ENABLE output Standard 24 V active (not selectable, for safety reasons)

OUT4 Warning Standard 0 V active (selectable in system configuration)

Attention If the external outputs or inputs are used, then the supply voltage for

6.2.1 Signal „Enable“

The signal ENABLE is always 24V active The signal is LOW (0V)

• during system operation via keyboard

• in case of system fault

• during a system test The signal is HIGH (24V)

• when the system is operational

Opto coupler outputs

the outputs / inputs needs to be connected.

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Manual

Double Sheet Detector-series I20

Communication with the PLC B0069991 / Rev. 1.7

6.2.2 Signal "Warning"

The “Warning“ signal is an additional output signal with fixed evaluation thresholds.

The signal becomes activated if the measurement result is below 80% or above 120% of the preset nominal value.

Application: If the warning signal is activated though a sheet is between the sensors, measuring

problems might have been occurred:

• Sensor distance changed

• Sheet too close to the transmitter / receiver

• Wrong type of sheet

• Sensor covering not sufficient (3 × sensor diameter)

Note If these requirements are met, but a warning signal is issued, then the

Teach-In must be repeated. The requirements from section “4.3 Sensor mounting“ should be observed.

Note The signal will also be activated if measurements without a sheet

(measurement value below 80%) are performed.

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

6.3 Timing diagrams

Notes for the following diagrams and descriptions

For all following diagrams and explanations, in the configuration menu item 11 the setting ”Level 0-1-2” has been selected “0V”.

If “24V” has been selected the outputs OUT1…OUT4 are inverted. Enable OUT0 will not be influenced by this.

6.3.1 External Single measurement

The measurement result remains frozen until a new action is initiated. At the moment of changing the output signals, an undefined condition can occur at the outputs, i.e.

all outputs or none can be active. If this condition occurs the outputs have to be interrogated again.

OUT 0

Enable

IN 1-9

Communication with the PLC

Meas. start

IN 0

OUT 1

0-sheet

1-sheet

2-sheet

warning

OUT 3

OUT 2

OUT 4

min. 10ms max.4ms

min. 4ms

1 Check whether the output OUT0 “Enable” has been switched to HIGH, otherwise a fault condition is

existing.

2 Before starting a measurement all inputs must be LOW for 10ms.

3 Switch the input IN0 “Measurement Start” to HIGH for at least 4 ms.

4 After max. 4ms the measurement result is available at the outputs OUT1…OUT3.

5 After point 4 or 4 ms after point 3 switch the input IN0 “Measurement Start” to LOW.

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Note In case of fault the signal “Enable” will be switched to LOW.

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Double Sheet Detector-series I20

Communication with the PLC B0069991 / Rev. 1.7

6.3.2 External Continuous measurement / External Special

The control unit measures continuously as long as the signal “Measurement Start” is switched to HIGH. If the signal “Measurement Start” is switched to LOW, the measurement is aborted and the last measuring result is frozen until a new cycle is initiated.

When approaching the sheet, the outputs signals switch from 0-sheet to 1-sheet (or 1-sheet to 2sheet respectively). An undefined condition can occur at the outputs, i.e. all outputs or none can be active. If this condition occurs the outputs have to be interrogated again.

IN 0

Enable

Meas. start

0-sheet

OUT 0

IN 1-9

OUT 3

OUT 1

1-sheet

2-sheet

warning

min.10ms

max.4ms 1 ms 1 ms

456

min. 4ms

OUT 2

OUT 4

1 Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation), otherwise a

fault condition is existing.

2 Before starting a measurement all inputs must be LOW for 10ms.

3 Switch the input IN0 “Measurement Start” to HIGH.

4 After max. 4ms the measurement result is available at the outputs OUT1…OUT3.

5 The measurement result of the second measurement is available at the outputs.

The measurement starts again.

6 The measurement result of the third measurement is available at the outputs.

The measurement starts again.

7 Switch the input IN0 “Measurement Start” to LOW.

The measurement is aborted, the last measurement result is now available at the outputs OUT1…OUT3. The measurement result is frozen until a new cycle is initiated.

Note In case of fault the signal “Enable” will be switched to LOW.

Note In the “extern special” measurement mode the highest measured

value will be displayed and held at the outputs until a new measurement is started.

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

6.3.3 System test (Sensor gap control)

In order to check the function of the unit it is possible to check the sensor gap. This test can also be used as functional check.

No sheet must be present during this test. If the sensor gap has changed, then the unit reports an error and the output OUT0 “Enable” remains LOW. If the gap is the same as during Teach-In and the unit is working properly, then the sensor gap control will be performed fault free.

IN0-5, 7-9

IN6

OUT0

OUT4, 3, 2, 1

Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation), otherwise a fault condition is existing.

All inputs must be LOW for 10 ms before “Test Sensor gap” is activated. No sheet must be present

between the sensors. Switch input IN6 “Test Sensor gap” to HIGH.

3 4

Within 10ms all outputs are switched to LOW. The system now performs a sensor gap test. The test will be finished within 300ms. The system now waits for the input IN6 being switched to LOW.

Switch the input IN6 “Test Sensor gap” to LOW.

5 6

All outputs are switched to HIGH. In case of fault the ouput OUT0 “Enable” switches to LOW. If “Measurement: Demo mode” is configured it is not possible to interrogate the outputs OUT1…OUT4, because the measurement restarts automatically after finishing the test. Therefore the unit must be configured to “Measurement: external”.

System test

Enable

0-1-2-sheet; Warning

min. 10ms

max.10ms

min. 10ms

Communication with the PLC

max. 10-300ms

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Double Sheet Detector-series I20

Communication with the PLC B0069991 / Rev. 1.7

6.3.4 Program switching

All 255 measuring programs can be selected via the PLC inputs IN1 to IN9.

Attention: The inputs IN2 to IN9 are used also for functions other then the selection of the

measuring programs. This means that the timing has to be followed exactly.

OUT0

IN1

IN2-9

IN0

OUT1, 2, 3, 4

Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation), otherwise a fault condition is existing.

Before selecting a measuring program all inputs must be switched to LOW for 10 ms.

2 3

Switch the input IN1 “program selection” to HIGH.

4 Simultaneously with 3 or delayed switch the binary value to IN2…IN9. 5 Max. 10ms after having switched IN1 “Program selection” the outputs OUT1…OUT4 are switched to

LOW.

After the binary value has been present for a minimum of 10 ms, switch the input IN1 “Program

selection” to LOW. Simultaneously with 6 or delayed switch back the binary values at IN2…IN9 (switch to LOW).

7 8

After a maximum time of 250ms the outputs OUT1…OUT3 are switched to HIGH. If the configuration “Measurement: Demo mode” has been selected, measurement will re-start automatically (if a valid program has been selected). If the configuration “Measurement external” has been selected, the operation of the unit is then performed via the PLC.

Note:

Program-No. Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

1 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 1 3 0 0 0 0 0 0 1 0

… … … … … … … … … 254 1 1 1 1 1 1 0 1 255 1 1 1 1 1 1 1 0

Not used 1 1 1 1 1 1 1 1

Enable

Program switching

Bit 0-7

Meas. Start

0-1-2-sheet; Warning

max. 10ms

min. 10ms

2 8

>=0ms

total switching time > 80-320 ms

* dependin

on nominal thickness and material

>=0msmin. 10ms 10-250ms*

6 7

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

6.3.5 Clear 2-sheet / Clear 0-1-2-sheet, warning outputs

In case of double sheet detection clearing is possible only if the unit is adjusted to “Hold 2-Sheet”.

IN 5

OUT 3

OUT 2

Enable

Clear 2-sheet / Clear outputs

0-sheet

1-sheet

OUT 0

IN 0-4, 6-9

Communication with the PLC

2-sheet

OUT 1

Warni ng

OUT 4

min.10ms

1 Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation),

otherwise a fault condition is existing.

2 All inputs must be LOW for 10ms before “Clear 2-Sheet” is activated.

3 Switch input IN5 "Clear 2-Sheet" to HIGH.

4 Within 10ms the outputs OUT1…OUT4 are set to HIGH.

5 After a minimum time of 10ms switch the input IN5 “Clear 2-Sheet” to LOW.

6 Within 10ms the unit can be operated via the inputs.

max.10ms max.10ms

min.10ms

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Manual

Double Sheet Detector-series I20

Communication with the PLC B0069991 / Rev. 1.7

6.3.6 Zero adjust

For performing a zero adjust no sheet must be present between the sensors.

Enable

OUT 0

IN 0-9

(without IN 3/4)

Te ac h -i n

IN 3

range

Zero adjust

IN 4

OUT 4, 3, 2, 1

0-1-2-sheet; warning

min.10ms max.10ms

min.10ms

max.150sec.

1 Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation),

otherwise a fault condition is existing.

2 Before initiating the zero adjust all inputs must be switched to LOW for 10ms.

No sheet must be present between the sensors.

3 Switch the input IN4 “zero adjust” to HIGH.

Then the system performs the zero adjust, which will be completed within 15 seconds. Now the system waits for the input IN4 to be switched to LOW:

4 Within 10ms the outputs OUT1…OUT4 are switched to LOW.

5 After point 4 or 10ms after point 3 switch the input IN4 “zero adjust” to LOW.

6 The outputs OUT1…OUT4 switch to HIGH.

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

6.3.7 Material detection NF

For performing a “Material detection NF”, a non-ferrous sheet with nominal thickness must be present between the sensors.

Enable

OUT 0

IN 0-9

(without IN 3/8)

Teach-in

IN 3

range

Material detection NF

IN 8

OUT 4, 3, 2, 1

0-1-2-sheet; warning

Communication with the PLC

min.10ms

max.10ms

min.10ms

max.7sec.

1 Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation), otherwise a

fault condition is existing.

2 Before initiating the material detection, all inputs must be switched to LOW for 10ms.

A sheet of nominal thickness must be present between the sensors.

3 Switch the input IN8 “material detection” to HIGH.

4 Within 10ms the outputs OUT1…OUT4 are switched to LOW.

Now the system determines the electrical conductivity of the NF material. Within 7 seconds the material detection is completed. Now the system waits for the input IN8 “material detection” being switched to LOW.

5 After point 4 or 10ms after point 3 switch the input IN8 “material detection” to LOW.

6 The outputs OUT1…OUT4 switch to HIGH.

Note: If “FE” (ferromagnetic material) or operating mode “Frequency” is set, then the material

detection for NF will also be performed, but will be without any effect. There will also no fault message be displayed.

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Manual

Double Sheet Detector-series I20

Communication with the PLC B0069991 / Rev. 1.7

6.3.8 Static Teach-In 1-sheet (Part A)

During the static Teach-In one sheet of nominal thickness must be present between the sensors. In the operating mode "Frequency" (Monitoring Parts for Hardend / Tempered Properties and Materials Mix up) part A must be placed in the sensor gap.

Enable

OUT 0

IN 0-9

(without IN 2/3)

Teach-in

IN 3

range

Teach-in

IN 2

1-sheet

OUT 4, 3, 2, 1

0-1-2-sheet; warning

min.10ms

max.10ms

min.10ms

max.7sec.

1 Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation), otherwise a

fault condition is existing.

2 Before initiating the static Teach-In 1-sheet, all inputs must be switched to LOW for 10 milliseconds.

One sheet of nominal thickness must be present between the sensors.

3 Switch the input IN2 “Teach-In 1-sheet” to HIGH.

4 Within 10ms the outputs OUT1…OUT4 are switched to LOW.

Then the system performs a Teach-In 1-sheet, which will be completed after max. 7 seconds. Now the system waits for the input IN2 “Teach-In 1-sheet” being switched to LOW.

5 After point 4 or 10ms after point 3 switch the input IN2 “Teach-In 1-sheet” to LOW.

6 The outputs OUT1…OUT4 switch to HIGH.

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

6.3.9 Dynamic Teach-In 1-sheet (Part A)

During the dynamic Teach-In one sheet of nominal thickness must be driven through the sensors. In the operating mode "Frequency" (Monitoring Parts for Hardend / Tempered Properties and Materials Mix up) part A must be drive through the sensor gap.

OUT 0

IN 0-9

(without IN 2/3)

IN 3

IN 2

Enable

Teach-in range

Teach-in 1-sheet

Communication with the PLC

OUT 4, 3, 2, 1

0-1-2-sheet; warning

min.10ms

max.

10ms

Teach-in range

>= ms



0,5sec.

1 Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation), otherwise a

fault condition is existing.

2 Before initiating the Teach-In 1-sheet all inputs must be switched to LOW for 10ms.

3 The Teach-In is selected by switching the input IN3 to HIGH.

4 Switch the input IN2 “Teach-In 1-sheet” to HIGH.

5 Within 10ms the outputs OUT1…OUT4 are switched to LOW.

6 After the sheet has been driven through the sensors the input IN3 is switched to LOW.

7 Now switch the input IN2 “Teach-In 1-sheet” to LOW.

8 The Teach-In is completed within 0,5s and the outputs OUT1…OUT4 switch to HIGH.

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Manual

Double Sheet Detector-series I20

Communication with the PLC B0069991 / Rev. 1.7

6.3.10 Static Teach-In 2-sheet (Part B)

During the static Teach-In two sheets of nominal thickness must be present between the sensors. In the operating mode "Frequency" (Monitoring Parts for Hardened / Tempered Properties and Materials Mix up) part B must be placed in the sensor gap.

Enable

OUT 0

IN 0-9

(without IN 3/7)

Teach-in

IN 3

range

Teach-in

IN 7

2-sheet

OUT 4, 3, 2, 1

0-1-2-sheet; warning

min.10ms max.10ms

min.10ms

max.1sec.

1 Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation), otherwise a

fault condition is existing.

2 Before initiating the Teach-In 2-sheet all inputs must be switched to LOW for 10ms.

Two sheets of nominal thickness must be placed between the sensors.

3 Switch the input IN7 “Teach-In 2-sheet” to HIGH.

4 Within 10ms the outputs OUT1…OUT4 are switched to LOW.

Then the system performs the Teach-In procedure, which will be completed within 7 seconds. Now the system waits for the input IN7 being switched to LOW.

5 After point 4 or 10ms after point 3 switch the input IN7 “Tech-In 2-Sheet” to LOW.

6 The outputs OUT1…OUT4 switch to HIGH.

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

6.3.11 Dynamic Teach-In 2-sheet (Part B)

During the dynamic Teach-In two sheets of nominal thickness must be driven through the sensors. In the operating mode "Frequency" (Monitoring Parts for Hardened / Tempered Properties and Materials Mix up) part B must be drive through the sensor gap.

OUT 0

IN 0-9

(without IN 3/7)

IN 3

IN 7

Enable

Teach-in range

Teach-in 2-sheet

Communication with the PLC

OUT 4, 3, 2, 1

0-1-2-sheet: warning

min.10ms

max.

10ms

Teach-in range

>=0ms 0,5sec.

1 Check whether the output OUT0 “Enable” has been switched to HIGH (ready for operation), otherwise a

fault condition is existing.

2 Before initiating the Teach-In 2-sheet all inputs must be switched to LOW for 10ms.

3 The Teach-In is selected by switching the input IN3 to HIGH.

4 Switch the input IN7 “Tech-In 2-sheet” to HIGH.

5 Within 10ms the outputs OUT1…OUT4 are switched to LOW.

6 After the sheet has been driven through the sensors the input IN3 is switched to LOW.

7 Now switch the input IN7 “Tech-In 2-sheet” to LOW.

8 The Teach-In is completed within 0,5s and the outputs OUT1…OUT4 switch to HIGH.

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Manual

Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

6.3.12 Reset error

With the “Reset error” function uncritical faults can be redressed. Critical errors like “cable rupture” can only be redressed with the control unit keys.

1 Before the “Reset error” is initiated, all inputs must be LOW for 10 ms.

2 Switch input IN9 “Reset error” to HIGH.

3 Within 10ms all outputs are switched to LOW.

If the fault can be reset, the output OUT0 will be set to HIGH.

4 Switch the input IN9 “Reset error” to LOW.

5 Within 10ms all outputs are switched to HIGH.

6.4 Internal control (Demo mode)

In this operating mode the system continuously executes measurements and activates OUT0 … OUT4.

In general, this operating mode is suitable for demonstration purposes only. Prerequisites:

• Supply voltage applied

• System parameter “Measurement mode” set to “demo”

• Teach-In has been executed

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

7 Start-up

7.1 Initially applying power to the system

The I20 is designed for an operating voltage of 24 VDC (+6 V / -4 V). This voltage is to be checked before applying power. The control unit is automatically switched on by applying the power.

After applying power, the type of system and the version number are briefly displayed. Then the system switches into that measurement menu, which was active before the unit was switched off. If the equipment does not power up, the fuse should be checked.

7.2 Start screen

After applying the supply voltage to the system, the start screen will be shown until the unit has initialized.

ROLAND ELECTRONIC

I20

SV: 21

Fig. 28: Start screen

It shows the type of system and the software version. After the control unit is fully operational, the Start screen is replaced by the operations screen.

Start-up

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

7.3 Operation

Note: The system is factory adjusted for “external continuous measurement“.

After applying power to the system and the version number are briefly displayed. Afterwards the system switches into that measurement menu which was active before the unit was switched off.

Therefore the system functions only if the signal “measurement start“ is activated via the PLC input. The modification of the configuration is

described in the following sections.

Fig. 29: Frontal view of the I20 with enlarged display detail

LED functions (symbols above the keys)

Norm

Enable

ON, if the measured value reaches (or falls short of) the lower limit value.

ON, if the measured value is within the lower and upper limit values.

ON, if the measured value reaches (or exceeds) the upper limit value.

- blinks, if a fault is present

- ON, if the equipment is in measurement mode

- OFF, during parameter programming with the keyboard

Key functions (symbols belo w the keys)

▲

▼

Enter Menu

Changes the parameters (forward)

Changes the parameters (backwards)

Selects a parameter for changing and confirming the change

Activates the menu level, for deleting a fault message and exiting the menu level.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

7.4 Configuration menu

7.4.1 Main menu structure

Button

Config.

Review

Program parameter

System adjustment

System configuration

change

(password)

Button

ENTER

Unit-information

7.7

Parameters of the respective measurement program

7.8

Adjustment of this system / sensors

7.9

General system configuration

Start-up

Data backup

Firmware update

Fig. 30: Main structure of configuration menu

7.10

Backup of the data stored in the system via virtual RS232 (USB)

7.11

Updating the firmware of the system

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Manual

Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

7.4.2 Sub structure “Program parameters” (details in 7.7)

7.4.2.1 Sub structure “Program parameters” (except in operating mode “frequency)

Program No.

Sensor number

Nominal thickness

Material

Lower limit value TL

1 … 255

Sensor number 1 / 2 / 3 / 4 / 1+2 / 1+3 / 1+4 / 2+3 / 2+4 / 3+4 / 1+2+3 / 1+2+4 / 1+3+4 / 2+3+4 / 1+2+3+4

0.000 … 15.00 mm (only in operating mode „Standard)

– FE – NF (non-ferrous, with conductivity value) – NF (non-ferrous, without conductivity, unit detects it)

TL% (0-99%) and absolute

Upper limit value TU

Settling time desired / actual 2 / 4 / 8 / 15 / 25 / 100 / 250 ms

Teach-in 1-sheet

Teach-in 2-sheet

Fig. 31: Sub structure „program parameters“

TU% (100-180%) and absolute

– ok – missing – dynamic all / single – static all / single

– no – dynamic all / single – static all / single

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Manual

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

7.4.2.2 Sub structure “Program parameters” of the operating mode “Frequency” (Monitoring Parts for Hardened / Tempered Properties and Materials Mix up)

Program No.

Sensor number

Frequency

Materialnot available

Lower limit value TL

1 … 255

Sensor number 1 / 2 / 3 / 4 / 1+2 / 1+3 / 1+4 / 2+3 / 2+4 / 3+4 / 1+2+3 / 1+2+4 / 1+3+4 / 2+3+4 / 1+2+3+4

8 Hz - 25 KHz

TL% (0-99%) and absolute

(depending on sensor type)

Start-up

Upper limit value TU

Settling time desired / actual 2 / 4 / 8 / 15 / 25 / 100 / 250 ms

Teach-in part A

Teach-in part B

Fig. 32: Sub structure „program parameters“ of the operating mode Frequency

TU% (100-180%) and absolute

– ok – missing – dynamic all / single – static all / single

– no – dynamic all / single – static all / single

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Manual

)

Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

7.4.3 Sub structure “System adjustment” (details in 7.8)

System adjustment

Zero adjust

Test sensor distance

Deviation distance

Sensors distance mm

– no – yes / all (for all sensors selected in the

system configuration under “sensor number”

– no – yes

Indication of deviation from taught sensor gaps

Indication – mm – inch

Control sensors

Fig. 33: Sub structure „system adjustment“

– no – yes

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Manual

–

Double Sheet Detector-series I20

B0069991 / Rev. 1.7

7.4.4 Sub structure “System configuration” (details in 7.9)

ystem parameter

Language german / english / italian / french / spanish

System type

Dimension

not available

Indication Time

not available

Delete Prog.Para.

Password active

Password 0000 - 9999

Standard / FE+AL 0,5 - 3 mm / FE+AL 0,1 - 0,8 mm / FE + Austenit 0,1 - 1 mm / FE + Austenit 0,5 - 3 mm / Frequency / Damping mode

mm / inch (for system type “standard”) / % (for system type “non standard”)

0,0 - 2 seconds holding time

no / yes

Start-up

Sensor type

Default settling time

Measuring mode

Hold 2-sheet

not available

Output level 0-1-2

Auto. Prog.select yes / no

IN/OUT PLC voltage

External adjust

Internal system zero

Internal system gain

not available

1, 2, 3, 4 (according to system version)

IS/IE42-30GS / IS/IE30-20GS / ISQ/IEQ42S / ISQ/IEQ160S

2 / 4 / 8 / 15 / 25 / 100 / 250 ms

ext. single meas. / demo mode / ext. c ontinuous meas. / ext. special

yes / no

0VDC / +24VDC

monitoring

– no monitoring

yes / no

only for Service personnel

Diagnostic factor / thickness range

Compensation factor

System info versions of Software, Hardware-Proc.-board, Hardware-Analog-boar

scheduled

Fig. 34: Sub structure configuration

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

7.5 General information regarding the configuration

Note The correct configuration depends on the communication with the PLC,

The following rules apply to the operation in the configuration mode:

• The configuration mode is activated (while in measurement mode) by pressing the MENU key.

• The configuration mode is terminated or cancelled by pressing the MENU key.

• The selected / set parameters can be changed when the items are blinking in the display.

• The selected / set parameters are activated by pressing the ENTER key.

Note The systems info and bus info is displayed by pressing the ENTER key in the base menu (compare also system parameter 27).

on the measurement task and the connected components.

7.6 Changing, setting-up or checking the configuration

In order to select, set-up or check the system / program parameters, press the MENU key.

Here either reviewing or changing the configuration can be selected. Configuration review: The program / adjust / system parameters cannot be changed.

The measurement mode is not interrupted.

configuration review

Fig. 35: Indication after calling-up the menu

Configuration change: All program / adjust / system parameters can be changed after entering the password. The following menu option is shown.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

configuration change

Fig. 36: Selecting the configuration mode

Available configuration modes:

• Configuration program parameter

• Configuration adjustment parameters

• Configuration system adjust

• Data backup

• Firmware update Program parameters are application specific adjustments (e.g. input of nominal sheet thickness).

Adjustment parameters are parameter, which are only valid for this individual system; they cannot be transferred to other systems. System parameters are general adjustments (e.g. language).

Start-up

Note After exiting the configuration mode the password remains active for five

minutes. Thus other configuration adjustments can be made, without reentering the password. If no key is pressed for five minutes (while in the menu level), then the program changes to the measurement mode.

For changing parameters, the password must be entered.

password xxxx

Fig. 37: Password request

Each blinking digit can be changed with the arrow keys and confirmed with ENTER. After having

entered the correct password, the following menu appears for the adjustment of the configuration mode. The password is factory set to “0000”.

If the entered password is incorrect then the cursor returns to the first digit of the password and the

input must be repeated. The input of the password can be aborted by pressing the MENU button.

Note A fault is generated if PLC commands are executed while entering the

password or changing parameters.

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Manual

Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

7.7 Program parameters

7.7.1 Program parameters for the double sheet detection

This menu structure is valid for the system types a – f (For details refer to chapter 3.2) The program parameters contain the information required for the various measurement programs.

For accessing the program parameters, select the mode “configuration program parameter“ and

confirm with ENTER.

Program parameter 1: Selecting the measuring program to be configured.

Program Parameter: 1 Program Number 1

Fig. 38: Selecting the program to be configured

Here the measuring program (1-255) to be configured is selected. All following adjustments apply to the selected program.

Program parameter 2: Selecting the sensors to be used for measurement.

Program Parameter: 2 Sensor no./Sequence

Fig. 39: Sensor number / Sequence

Here the sensor pair /sensor pairs is / are selected, which are to be used for measurement. Possible choices:

• 1 / 2 / 3 / 4

• 1+2 / 1+3 / 1+4 / 2+3 / 2+4 / 3+4

• 1+2+3 / 1+2+4 / 1+3+4 / 2+3+4 / 1+2+3+4

Program parameter 3: Specifying the nominal thickness and material of the sheet to be

measured in mm or inch.

Program Parameter: 3 nominal thickness

0.90mm

This parameter is only in the operating mode „Standard” available.

Fig. 40: Adjusting the nominal thickness

Here the nominal thickness of the sheet to be measured is specified. Normally, the nominal thickness is the sheet thickness used for Teach-In.

Attention A change of the nominal thickness deletes the values

determined during Teach-In. A new Teach-In is required.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

Program parameter 4: Specifying the material of the sheets to be measured.

Program Parameter: 4 Material ferrous steel

Fig. 41: Selection of material to be measured

Possible choices:

• Fe (ferrous): Magnetic material.

• NF (non-ferrous): Nonmagnetic material (e.g. Aluminum, austenitic Stainless Steel) with known conductivity.

• NF?: Nonmagnetic material (e.g. Aluminum, austenitic Stainless Steel) with unknown conductivity. During Teach-In, the system determines by itself the conductivity of the material between the sensors.

The user will be asked whether the conductivity is to be determined

Program parameter 5: Setting the percentage threshold of the lower limit value.

now or at a later time.

Start-up

Program Parameter: 5

lower threshold

80% 6.608 mm

Fig. 42: Adjusting the upper limit

Value range: between 0% and 99% of the nominal value, with simultaneously displaying the absolute limit value.

Program parameter 6: Setting the percentage threshold of the upper limit value.

Program Parameter: 6

upper threshold

120% 12.390 mm

Fig. 43: Adjusting the lower limit

Value range: between 100% and 180% of the nominal value, with simultaneously displaying the absolute limit value.

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

Program parameter 7: Adjusting the nominal settling time and indicating the actual settling time.

Program Parameter: 7 Settling time desired value:250ms actual value: 250ms

Fig. 44: Adjusting the nominal settling time

In the upper line the „desired value“ of the settling time must be entered. If the achievable settling time exceeds the „desired value“, the system selects the next larger possible value and indicates this value in the line below.

Possible choices:

• 2 / 4 / 8 / 15 / 25 / 100 / 250 ms In general, the „desired value“ should be set such that it fits the transportation speed and the sheet

length.

• Fast transportation and short sheets require shorter measurement times

Program parameter 8: Teach-In for 1-sheet

Program Parameter: 8 Teach-In 1-sheet ok

Fig. 45: Status of Teach-In

Possible indications:

• missing: A Teach-In for 1-sheet has not been performed

• OK: A Teach-In for 1-sheet was already performed

• statical: A static Teach-In for 1-sheet will be performed

• dynamical: A dynamic Teach-In for 1-sheet will be performed

Note In order to use a parameter set for measurement, a Teach-In for

1-sheet must have been performed.

If no Teach-In is present or if a Teach-In for 1-sheet must be repeated, select “statical“/“dynamical”.

• Statical: The system will perform a punctual Teach-In for 1-sheet.

• Dynamical: The sheet with nominal thickness is moved through the sensor gap while performing the Teach-In for 1-sheet.

Note The position of the sheet for Teach-In for 1-sheet must match with

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the position in measurement operation. Otherwise the

measurement result can become faulty.

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B0069991 / Rev. 1.7

Static Teach-In 1-sheet:

Program Parameter: 8 Teach-In 1-sheet feed 1-sheet then press ENTER

Fig. 46: Teach-In procedure for 1-sheet

The sheet must be moved into mid-position between the sensors. With the ENTER key the

Teach-In for 1-sheet will be performed.

Dynamic Teach-In 1-sheet:

Program Parameter: 8

Teach-In 1-sheet

drive 1-sheet through

then press ENTER

Fig. 47: Teach-In procedure for 1-sheet

The sheet must be moved through the sensor gap in mid position. With the ENTER key the measurement value will be stored.

The dynamical Teach-In for 1-sheet is suitable especially for magnetical conveyor belt applications.

After the Teach-In for 1-sheet the following message is shown:

Start-up

Program Parameter: 8

Teach-In 1-sheet

finished

push ENTER

Fig. 48: Teach-In finished

Program parameter 9: Teach-In for 2-sheet

Program Parameter: 9

Teach-In 2-sheet

Fig. 49: Status of Teach-In

Possible indications:

• no: No Teach-In for 2-sheet is to be performed

• static: A statical Teach-In for 2-sheet will be performed

• dynamic: A dynamical Teach-In for 2-sheet will be performed

If a Teach-In for 2-sheet is to be repeated, select “statical“ resp. “dynamical”.

• Static: The system will perform a punctual Teach-In for 2-sheet.

• Dynamic: The double sheet with nominal thickness is moved through the sensor gap while performing the Teach-In for 2-sheet.

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

Note The position of the sheet for Teach-In for 2-sheet must match with the

Static Teach-In 2-sheet:

position in measurement operation. Otherwise the measurement result can

become faulty.

Program Parameter: 9

Teach-In 2-sheet feed 2-sheet then press ENTER

Fig. 50: Teach-In procedure for 2-sheet

The double sheet must be moved into mid-position between the sensors. With the ENTER key the

Teach-In for 2-sheet will be performed.

Dynamic Teach-In 2-sheet:

Program Parameter: 9 Teach-In 2-sheet drive 2-sheet through then press ENTER

Fig. 51: Teach-In procedure for 2-sheet

The double sheet must be moved through the sensor gap in mid position. With the ENTER key the measurement value will be stored.

The dynamical Teach-In for 2-sheet is suitable especially for magnetical conveyor belt applications.

After the Teach-In for 2-sheet the following message is shown:

Program Parameter: 9 Teach-In 2-sheet

finished

push ENTER

Fig. 52: Teach-In finished

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

7.7.2 Program parameters for the (Monitoring parts for hardened / tempered properties and materials mix up)

This menu structure is valid for the system type g (for details refer to chapter 3.2) The program parameters contain the information required for the various measurement programs.

For accessing the program parameters, select the mode “configuration program parameter“ and

confirm with ENTER.

Program parameter 1: Selecting the measuring program to be configured.

Program Parameter: 1 Program Number 1

Fig. 53: Selecting the program to be configured

Here the measuring program (1-255) to be configured is selected. All following adjustments apply to the selected program.

Program parameter 2: Selecting the sensors to be used for measurement.

Start-up

Program Parameter: 2 Sensor no./ Sequence

Fig. 54: Sensor number / Sequence

Here the sensor pair /sensor pairs is / are selected, which are to be used for measurement. Possible choices:

• 1 / 2 / 3 / 4

• 1+2 / 1+3 / 1+4 / 2+3 / 2+4 / 3+4

• 1+2+3 / 1+2+4 / 1+3+4 / 2+3+4 / 1+2+3+4

Program parameter 3: Setting the measuring frequency

Program Parameter: 3

frequency

320 Hz

Fig. 55: Setting the measuring frequency

According the measuring task is selected here the frequency. Different frequencies are available, depending on the sensor type.

Note A change deletes the values determined during the Teach-In and

therefore requires a new Teach-In.

Program parameter 4: not available

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

Program parameter 5: Setting the percentage threshold of the lower limit value.

Program Parameter: 5

lower threshold

80%

Fig. 56: Adjusting the upper limit

Value range: between 0% and 99%

Program parameter 6: Setting the percentage threshold of the upper limit value.

Program Parameter: 6

upper threshold

120%

Fig. 57: Adjusting the lower limit

Value range: between 100% and 180%

Program parameter 7: Adjusting the nominal settling time and indicating the actual settling time.

Program Parameter: 7

settling time I20 desired value:250ms actual value: 250ms

Fig. 58: Adjusting the nominal settling time

Possible choices:

• 2 / 4 / 8 / 15 / 25 / 100 / 250 ms In general, the „desired value“ should be set such that it fits the transportation speed and the sheet

length.

• Fast transportation and short sheets require shorter measurement times

Program parameter 8: Teach-In for Part A

Program Parameter: 8 Teach-In part A ok

Fig. 59: Status of Teach-In Part A

Possible indications:

• missing: A Teach-In for Part A has not been performed

• OK: A Teach-In for Part A was already performed

• static: A static Teach-In for Part A will be performed

• dynamic: A dynamic Teach-In for Part A will be performed

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

If no Teach-In is present or if a Teach-In for Part A is to be repeated, select “statical“ / “dynamical”.

• Static: The system will perform a punctual Teach-In for Part A.

• Dynamic: Part A is moved through the sensor gap during Teach-In.

Static Teach-In Part A:

Program Parameter: 8 search max/min:XXXXX feed part A then press ENTER

Fig. 60: Teach-In procedure for Part A

Place part A into the sensor gap. With the value shown in the display the position with the largest value (positive) or respectively with the smallest value (negative) can be determined (depending on the application). The Teach-In for part A is completed by pushing the Enter Key.

Dynamic Teach-In Part A:

Note In order to use a parameter set for measurement, a Teach-In for Part A must have been performed.

Note The position of the Part A for Teach-In must match with the

position in measurement operation. Otherwise the measurement

result can become faulty.

Start-up

Program Parameter: 8 Teach-In part A drive part A through then press ENTER

Fig. 61: Teach-In procedure for Part A

The Part A must be moved through the sensor gap in mid position. With the ENTER key the measurement value will be stored.

After the Teach-In for Part A the following message is shown:

Program Parameter: 8 Teach-In part A

finished

push ENTER

Fig. 62: Teach-In finished

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

Program parameter 9: Teach-In for Part B

Program Parameter: 9 Teach-In part B ok

Fig. 63: Status of Teach-In Part B

Possible indications:

• no: No Teach-In for Part B is to be performed

• static: A static Teach-In for Part B will be performed

• dynamic: A dynamic Teach-In for Part B will be performed

If a Teach-In for Part B is to be repeated, select “static“ resp. “dynamical”.

• Static: The system will perform a punctual Teach-In for Part B.

• Dynamic: Part B is moved through the sensor gap during Teach-In.

Note The position of the Part B for Teach-In must match with the

position in measurement operation. Otherwise the measurement

result can become faulty.

Static Teach-In Part B:

Program Parameter: 9 search max/min:XXXXX feed part B then press ENTER

Fig. 64: Teach-In procedure for Part B

Place part B into the sensor gap. With the value shown in the display the position with the largest value (positive) or respectively with the smallest value (negative) can be determined (depending on the application). The Teach-In for part B is completed by pushing the Enter Key.

Dynamic Teach-In Part B:

Program Parameter: 9 Teach-In part B drive part B through then press ENTER

Fig. 65: Teach-In procedure for 2-sheet

The Part B must be moved through the sensor gap in mid position. With the ENTER key the measurement value will be stored.

After the Teach-In for Part B the following message is shown:

Program Parameter: 9 Teach-In part B

finished

push ENTER

Fig. 66: Teach-In finished

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

7.8 Adjustment parameters

Adjustment parameters are parameters, which are only valid for this individual system; they cannot be transferred to other systems.

Adjustment parameter 1: Zero adjust

The Zero adjust procedure must be performed at commissioning and after having exchanged a sensor.

Attention Before performing a Zero adjust procedure, verify carefully that no

sheet is in the sensor gap.

Adjust Parameter: 1 Zero adjust no

Fig. 67: Status of Zero adjust

Possible choices:

• no: no Zero adjust to be performed.

• all / yes: All sensors are zero adjusted at the same time. During the zero adjust the following message is shown:

Start-up

Adjust Parameter: 1 Zero adjust Zero adjust active

Maximum time 150 sec.

Fig. 68: Display during zero adjust

Note Fault messages are described in the chapter “9 Fault messages“.

When the zero adjust is completed, the following message appears:

Adjust Parameter: 1 Zero adjust no

Fig. 69: Zero adjust successfully completed

The zero adjust is now completed.

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

Adjustment parameter 2: Selection of sensor test.

Adjust Parameter: 2 test Sensor distance no

Fig. 70: Selection of sensor test

Possible choices:

• no: No sensor test will be performed.

• yes: The operator will be requested to remove all sheets. Then the system performs the sensor test. If the test was done error-free, “Sensor distance OK“ is displayed. If the test shows faulty results, “Sensor distance too small” or “Sensor distance too large” will be shown. Then the sensor distance should be checked / corrected.

Adjustment parameter 3: Indication of the deviation of the sensor distances found.

Adjust Parameter: 3

deviation distance

Fig. 71: Sensor distances

By pressing the ENTER key the deviation of the investigated sensor distances are indicated (when in „change“ mode).

Adjust Parameter: 3 OK range:-200...+200 A1: 79 A2: 82 A3: 80 A4: 85

Fig. 72: Indication of deviation of sensor distances

Adjustment parameter 4: Calculation of the sensor distances.

Adjust Parameter: 4

distance sensors

Fig. 73: Scheduled parameter

By pressing the ENTER key the distance is calculated (in mm / inch).

Adjustment parameter 5: Control of sensors.

Adjust Parameter: 5

control sensors

Fig. 74: Control of sensors

Possible choices:

• no: The sensor allocation will not be tested.

• yes: The sensors are checked for correct wiring / allocation. In case of fault-free test result „Sensor control OK“ will be shown.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

7.9 System parameters

Note The selected system configuration should be documented in the form

The general adjustments are specified by configuring the system parameters.

For accessing, select the “system parameter configuration“ mode and confirm with ENTER.

System parameter 1: Setting the dialogue language.

System Parameter: 1

language

english

Fig. 75: Selecting the dialogue language

Possible choices:

• English

• German

• Italian

• French

• Spanish

System parameter 2: Determining the type of system.

“System configuration“ in the chapter 13 “Appendix“ or in the equipment documentation. This information is required in case a system needs to be

exchanged.

Start-up

System Parameter: 2

system type

standard

Fig. 76: system type

Possible choices:

• Standard

• FE + AL 0,5 - 3 mm

• FE + AL 0,1 - 0,8 mm

• FE + Austenit 0,1 - 1 mm

• FE + Austenit 0,5 - 3 mm

• Frequency

• Damping mode

Note The measurement range can be determined in the sensor diagram for the

respective sensor (see chapter 2.3 “Sensors”).

For explanation of “System type” see chapter 3.2.

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Start-up B0069991 / Rev. 1.7

System parameter 3: Selecting the dimensions for the display (mm / inch).

When changing the measurement dimensions, then the sheet metal thicknesses of the stored program parameters are also converted into the new dimension.

System Parameter: 3 display value in mm

Fig. 77: Selecting the dimension for the display

Possible choices:

• mm / inch only if system type is “standard”.

• %mm / %inch only if system type is not “standard”.

System parameter 4: not available

System parameter 5: Setting the display time

System Parameter: 5

display time

2.0 s

Fig. 78: Setting the display time

The maximal measured values (peak values) will be indicated for the time specified here (holding time). This time is only for the display.

System parameter 6: not available

System parameter 7: not available

System parameter 8: Deleting all measuring programs.

System Parameter: 8

clear prog. param.

Fig. 79: Deleting of measuring programs

Possible choices:

• yes

• no

Attention The deletion cannot be undone.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

System parameter 9: Switching the password function on / off.

System Parameter: 9

Fig. 80: Switching the password on / off

Possible choices:

• yes

• no

System parameter 10: Determining a password.

password active

Attention If password protection is not activated, then all parameters can be

Start-up

accessed at any time. This is recommended only during starting-up the system. For daily operation the password function should be activated.

System Parameter: 10

set password I20

0000

Fig. 81: Determining a password

The factory setting of the password is “0000”.

System parameter 11: Specifying the number of connected sensors.

System Parameter: 11 pairs of sensors 1

Fig. 82: Specifying the number of sensors for a 4-channel unit

Possible choices:

• 1 pair of sensors

• 2 pairs of sensors

• 3 pairs of sensors

• 4 pairs of sensors

Attention Changing the current configuration will delete all stored program

parameters. This means that for all types of sheets the nominal thickness values must be re-entered and the Teach-In must be performed again.

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

System parameter 12: Specifying the type of sensor.

System Parameter: 12

sensor type

IS42-30 / IE42-30

Fig. 83: Specifying the type of sensor

Possible choices:

• IS42-30GS / IE42-30GS (also for ISQ42S / IEQ42S)

• IS20-30GS / IE20-30GS

• ISQ160S / IEQ160S

System parameter 13: Specifying the settling time.

System Parameter: 13

default settlingTime

250 ms

Fig. 84: Specifying the settling time

The settling time is entered here, which will be preset as “desired” settling time in the “Clear program parameters” step. This time will be used if the existing settling time is lost due to deletion of the program parameters and a usable setting is no longer available.

System parameter 14: Adjusting the measuring mode.

System Parameter: 14

measure mode

extern continuous

Fig. 85: Adjusting the measuring mode

Possible measurement modes:

• external single: The system measures once if the “Measurement start“ signal is applied

via the external PLC input. Each measurement must initiated separately. The notes in chapter 6.3.2 „timing diagram single measurement“ must be observed.

• demonstration: This mode of operation is intended for equipment demonstrations, but

not for normal process operation. The system executes measurements continuously.

• external continuous: The system executes measurements, as long as

the “Measurement start“ signal is applied via the external PLC input.

external special: As for “external continuous”, but: The highest value reached during a

measurement cycle is displayed and maintained at the outputs until a new measurement is started. This also applies for the outputs 0-1-2-Warning.

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

System parameter 15: Specifying the system reaction when 2-sheet is detected.

System Parameter: 15 hold if 2-sheets no

Fig. 86: Adjusting the 2-sheet reaction

Possible choices:

• no: The outputs (0-sheet, 1-sheet and 2-sheet) are activated according to the number of sheets between the sensors. The equipment does not block operation if double sheet is encountered.

• yes: The outputs (0-sheet, 1-sheet and 2-sheet) are activated according to the number of sheets between the sensors. If double sheet is detected, the output “2-sheet“ is activated and the equipment is blocked until the 2-sheet condition is cleared.

This condition can be cleared

- through the PLC (clear 2-sheet)

- through the keyboard

System parameter 16: not available

System parameter 17: Setting the output logic (0-sheet, 1-sheet, 2-sheet and warning outputs).

Start-up

System Parameter: 17

Output 0-1-2-warning

24V active

Fig. 87: Setting the output logic

Possible choices:

• 0 V: As shown in the timing diagrams and the wiring diagrams

• +24 V: The outputs 0-sheet, 1-sheet, 2-sheet and warning are inverted, i.e. the respective signals in the timing diagrams and wiring diagrams must be seen inverted.

Note The output “Enable“ is not affected thereby.

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Start-up B0069991 / Rev. 1.7

System parameter 18: Setting the method of program selection.

System Parameter: 18

automat.Prog.select.

Fig. 88: Setting the method of program selection

Possible choices:

• no: When the program is switched via Fieldbus or I/O, the program number will not be

stored. So the system always starts up with the program which was last selected by keyboard operation.

• yes: When the program is switched via Fieldbus or I/O, the program number will be stored. After applying power the system always starts up with the program which was stored last.

Attention If the program is switched often, the memory becomes loaded with

frequent writing cycles and thus becomes destroyed during the time (lifetime approx. 1.000.000 write cycles).

In this case „no“ should be selected here.

System parameter 19: Setting the monitoring of the PLC voltage.

System Parameter: 19

IN/OUT PLC Voltage

no monitoring

Fig. 89: Setting the monitoring of the PLC voltage

Possible choices:

• no monitoring

• monitoring If the parameter is set to “monitoring“ and the PLC voltage is not connected, a respective fault

message will be indicated. Remedy: connect the voltage and then confirm the fault message.

System parameter 20: Deactivating / activating the external adjust via fieldbus.

System Parameter: 20

external adjust

Fig. 90: Deactivating / activating the external adjust

Here the external adjust, which is possible via fieldbus with the signals “Teach-In“ and “zero adjust“, can be deactivated / activated.

Possible choices:

• yes

• no

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

System parameter 21: Setting the internal system zeroing.

System Parameter: 21

Internal analog Zero

Fig. 91: Setting the internal system zeroing

This parameter is only for the Service personnel.

System parameter 22: Setting the internal system gain.

System Parameter: 22

Internal analog Gain

Fig. 92: Setting the internal system gain

This parameter is only for the Service personnel.

System parameter 23: not available System parameter 24: not available System parameter 25: Diagnostic

Start-up

System Parameter: 25

diagnostic

Fig. 93: Diagnostic factors (fixed)

This system param. is used for the equipment diagnostics and shouldn´t be changed by the user.

System parameter 26: Strength of compensation:

System Parameter: 26

compensation factor

Fig. 94: Compensation strength

Projected parameter.

System parameter 27: System info:

I20-PR-S-4(1)SV: 1 HVH: 0 HVA: 0 IN/OUT (no Bus) Unit

Fig. 95: System info

1st line: Indication of the system type. The bracketed numeral is the number of activated

sensors, the numeral before is the number of measurement channels (2-channel or 4-

line Indication of the versions of Software (SV) and Hardware (Processor board und Analog

This info field can also be displayed during the regular operation by pressing the ENTER key.

channel).

board).

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Double Sheet Detector-series I20

Start-up B0069991 / Rev. 1.7

7.10 Data backup

For better prevention off loss of data, a data backup procedure is available for the system configuration and the parameter sets. The backup is made via the upper USB interface on the front panel. The secured data can be transferred to spare units in case of exchange after a failure. The data backup is accomplished with the RPP7 software available from ROLAND (for Win2000 / XP / Vista).

The data backup procedure can be selected in the menu configuration. The following menu is displayed during the data backup.

Parameter backup active

Fig. 96: Status of data backup

For backup of data, the upper USB slot on the front panel must be used.

7.11 Firmware update

Roland systems are permanently enhanced. In order to use new functions, firmware update is required.

For firmware update use the lower front panel USB slot.

Note The firmware update may be performed only by qualified personnel.

On the PC used for firmware update, the actual RPP7 software must be installed, and the desired firmware version (.bin file) must be available. The RPP7 software can be found on the supplied CD.

For performing the update, connect the Double Sheet Detector to the lower front panel USB

interface of the PC, using the supplied cable. Then select “Firmware Update” in the configuration mode.

FIRMWARE UPDATE connect USB(FLASH)

Fig. 97: Indication for activating firmware update

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Double Sheet Detector-series I20

B0069991 / Rev. 1.7

After the USB terminal has been connected to the computer, the following is shown.

FIRMWARE UPDATE

start pressing key

Fig. 98: Messages for activating firmware update

Simultaneously pressing the keys arrow  and ENTER activates the firmware update.

Bootloader active

Fig. 99: Start firmware update

The update will then be executed via the RPP7 software. For operating the RPP7 software please refer to chapter 10, “Maintenance”.

UP and ENTER

FIRMWARE UPDATE

Attention By pressing the both keys the program memory is deleted.

The firmware update must then be performed without disturbance,

in order to keep the system operational.

Start-up

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Blank page

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B0069991 / Rev. 1.7

8 Operation

8.1 Abbreviated operating instructions

Note The system is factory adjusted for “external continuous measurement“.

After applying power to the system and the version number are briefly displayed. Afterwards the system switches into that measurement menu which was active before the unit was switched off.

Therefore the system functions only if the signal “measurement start“ is activated via the PLC input. The modification of the configuration is

described in the following sections.

Operation

Fig. 100: Frontal view of the I20 with enlarged display detail

LED functions (symbols above the keys)

ON, if the measured value reaches (or falls short of) the lower limit value.

Norm

Enable

ON, if the measured value is within the lower and upper limit values.

ON, if the measured value reaches (or exceeds) the upper limit value.

- blinks, if a fault is present

- ON, if the equipment is in measurement mode

- OFF, during parameter programming with the keyboard

Key functions (symbols belo w the keys)

▲

▼

Enter Menu

Changes the parameters (forward)

Changes the parameters (backwards)

Selects a parameter for changing and confirming the change

Activates the menu level, for deleting a fault message and exiting the menu level.

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Double Sheet Detector-series I20

Operation B0069991 / Rev. 1.7

In the measuring mode the measured value can be read in the display. The control unit automatically compares the measured value with the adjusted thresholds. The result is transmitted via the interface to the PLC and also to the front panel LED's.

During the normal measurement process no further actions on the control units are necessary with the following few exceptions. The following situations require action directly at the control unit or an action via the field bus interface:

• Clear fault and error messages (see to chapter “9. Error messages, causes and remedies“)

• Teaching of new types of metal and sheet metal thicknesses (see section “7.7 Configuration of the program parameters“)

• Clearing a 2-sheet condition (if configured) The following notes for the measuring operations should be observed:

Note Do not adjust the upper limit (“TU“) above 150 %.

8.2 Entering a measurement program

8.2.1 Entering a measurement program for the double sheet detection

1 Push the MENU key, switch to "change" with the   keys and confirm with ENTER key

2 Enter the password (if active)

3 Switch to "program parameter" and confirm with ENTER key

4 Select the desired program number at the control unit 5 Select the active sensor 6 Enter the nominal dimension (nominal thickness of the sheet to be processed)

(only for system type “standard”) 7 Specify the material (if required, perform auto detect for NF material) 8 Adjust lower limit (“low“) to 80% (default setting) 9 Adjust upper limit (“up“) to 120% (default setting) 10 Perform a Teach-In

11 Return into the measurement mode with the MENU key

8.2.2 Entering a measurement program for the system type “Frequency” (Monitoring Parts for Hardened / Tempered Properties and Materials Mix up)

1 Push the MENU key, switch to "change" with the   keys and confirm with ENTER key

2 Enter the password (if active)

3 Switch to "program parameter" and confirm with ENTER key

4 Select the desired program number at the control unit 5 Select the active sensor 6 Select Frequency 7 Adjust lower limit (“low“) to 80% (default setting) 8 Adjust upper limit (“up“) to 120% (default setting) 9 Perform a Teach-In

10 Return into the measurement mode with the MENU key

100

ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33