Roland R1000, l20 Series Manual
Double Sheet Control R1000 series I20
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Double Sheet Detector R1000 series I20
with integrated fieldbus interface
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 gaps
► Galvanically isolated 3-bit input interface and 5-bit output interface
► Integrated fieldbus interface with process and parameter interface
Profibus DP
ControlNet
DeviceNet
Interbus-S
CanOpen
ProfiNet IO
CC-Link
EtherNet/IP
EtherCAT
Copyright
©
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.
Subject to change without further notice.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Table of contents
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
3
Declaration of conformity according to EC directives ..................................................................................... 7
1 Safety advices ........................................................................................................................................ 9
1.1 Safety instructions and warnings for user .......................................................................................... 9
1.2 Declaration of icons ............................................................................................................................ 9
1.3 Intended use ..................................................................................................................................... 10
1.4 Fieldbus terms .................................................................................................................................. 10
2 Technical data ...................................................................................................................................... 11
2.1 Technical data control unit I20 .......................................................................................................... 11
2.2 Versions of the control unit I20 ......................................................................................................... 12
2.3 Sensors ............................................................................................................................................. 13
2.4 Dimensions of the sensors ............................................................................................................... 17
2.5 Sensor cables ................................................................................................................................... 18
2.6 Scope of delivery (accessories) ........................................................................................................ 19
3 System description .............................................................................................................................. 21
3.1 Measurement principle ..................................................................................................................... 21
3.2 System type ...................................................................................................................................... 21
3.3 General hints for process reliability .................................................................................................. 23
3.4 Control unit ....................................................................................................................................... 24
3.5 Parameters of the control unit .......................................................................................................... 25
3.6 Application examples ........................................................................................................................ 32
3.7 Tailor Welded Blanks ........................................................................................................................ 38
3.8 Design information regarding transporting velocity ......................................................................... 38
3.9 Secondary magnetic flux .................................................................................................................. 40
4 Mounting ............................................................................................................................................... 41
4.1 General mounting instructions .......................................................................................................... 41
4.2 Dimensions of the system ................................................................................................................ 42
4.1 Mounting of sensors ......................................................................................................................... 45
4.2 Sensor mounting in magnetic conveyors ......................................................................................... 48
5 Electrical installation ........................................................................................................................... 51
5.1 General instructions .......................................................................................................................... 51
5.2 Configuration of connectors .............................................................................................................. 52
5.3 Connecting diagram - examples ....................................................................................................... 59
6 Communication with the PLC ............................................................................................................. 63
6.1 Fieldbus specific messages .............................................................................................................. 63
6.2 Data transmission communication.................................................................................................... 64
6.3 Process channel ............................................................................................................................... 65
6.4 Parameter channel ........................................................................................................................... 81
6.5 External I/O control ........................................................................................................................... 88
6.6 Fieldbus configuration files ............................................................................................................... 92
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
Table of contents
B0060191 / Rev. 1.7
4
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Start-up ............................................................................................................................................... 101
7.1 Initially applying power to the system ............................................................................................ 101
7.2 Start screen .................................................................................................................................... 101
7.3 Operation ....................................................................................................................................... 102
7.4 Configuration menu ........................................................................................................................ 103
7.5 General information regarding the configuration ........................................................................... 107
7.6 Changing, setting-up or checking the configuration ...................................................................... 108
7.7 Program parameters ...................................................................................................................... 110
7.8 Adjustment parameters .................................................................................................................. 120
7.9 System parameters ........................................................................................................................ 122
7.10 Data backup ................................................................................................................................... 132
7.11 Firmware update ............................................................................................................................ 133
8 Operation ............................................................................................................................................ 135
8.1 Abbreviated operating instructions ................................................................................................ 135
8.2 Entering a measurement program ................................................................................................. 136
8.3 Zero adjust (after sensor exchange) .............................................................................................. 137
8.4 Teach-In ......................................................................................................................................... 137
9 Fault messages, causes and remedies ........................................................................................... 139
9.1 Faults concerning Memory ............................................................................................................ 140
9.2 Faults concerning USB data transmission (virtual RS232) ............................................................ 141
9.3 Faults concerning system operation .............................................................................................. 141
9.4 Faults concerning Keyboard .......................................................................................................... 141
9.5 Faults concerning Fieldbus interface ............................................................................................. 142
9.6 Faults concerning Sensor test ....................................................................................................... 142
9.7 Faults concerning Teach-In / Zero adjust ...................................................................................... 143
9.8 Faults concerning Sensors / Sensor cables .................................................................................. 143
9.9 Faults concerning Hardware .......................................................................................................... 143
9.10 Faults concerning Supply voltage .................................................................................................. 144
9.11 Other faults .................................................................................................................................... 144
10 Maintenance ....................................................................................................................................... 145
10.1 Replacement of sensors ................................................................................................................ 145
10.2 Exchange of control unit ................................................................................................................ 145
10.3 Replacement of fuses .................................................................................................................... 146
10.4 Data backup via the fieldbus interface ........................................................................................... 146
10.5 Data backup via USB interface ...................................................................................................... 146
10.6 Firmware update via USB interface ............................................................................................... 147
10.7 Spare parts .................................................................................................................................... 147
11 Technical records .............................................................................................................................. 149
11.1 Exchange of equipment ................................................................................................................. 149
11.2 Fieldbus configuration files ............................................................................................................ 149
11.3 Parameter channel commands ...................................................................................................... 150
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Table of contents
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12 Order data ........................................................................................................................................... 157
12.1 Versions of control unit I20 ............................................................................................................. 157
12.2 Sensors ........................................................................................................................................... 158
12.3 Cables ............................................................................................................................................. 159
12.4 Cable plugs and cable sockets ....................................................................................................... 159
12.5 Other accessories (within scope of delivery) .................................................................................. 159
13 Appendix ............................................................................................................................................. 161
13.1 System configuration form .............................................................................................................. 161
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
Safety advices B0060191 / Rev. 1.7
6
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Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Safety advices
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Declaration of conformity according to EC directives
Manufacturer: Roland Electronic GmbH
Otto-Maurer-Str. 17
DE 75210 Keltern
Product name:
I20
Product type:
Double Sheet Detector R1000-series
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
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
Managing Director
Place, Date Signature Function of the signer
The declaration confirms the compliance with the cited directives. However, it is not any implied warranty of fitness for a
particular purpose especially as it may relate to product liability.
The safety instructions and warnings must be observed.
ISO 9001 : 2008
Reg.-no. 5152 QM08
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
Safety advices B0060191 / Rev. 1.7
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Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Safety advices
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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. 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.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
Technical data B0060191 / Rev. 1.7
10
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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.
1.4 Fieldbus terms
Within this manual the following Field bus specific expressions are used:
Term used in the manual Field bus specific expression
Master Scanner
Slave ControlNet adapter / node
Baud rate Data rate
Bus address Mac ID / node address
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Technical data
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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-xx-S I20-4-xx-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-xx-S-FP I20-4-xx-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 or fieldbus
3 galvanically isolated
optocoupler inputs 24 VDC with
common external supply
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
5 potential free outputs
with positive external supply
Specification:
- max. switching voltage: 30 VDC
- max. switching current: 500 mA
Fieldbus interface possibilities
Profibus-DP interface according to EN 50170, protocol version 1.10, max. baud
rate 12 Mbit/s
ControlNet communication adapter (profile number 12) according to int.
ControlNet specification
DeviceNet communication adapter (profile number 12) according to ODVA
specification (group two only server)
Interbus-S interface, certification protocol no. 440 (500 kbit/s)
CanOpen interface, according to DS301 v4.02 compliant
ProfiNet IO interface
CC-Link V1
EtherNet/IP
EtherCAT
Virtual RS232 interface (via USB) for data backup
USB interface for Firmware update
Attention In case of inductive load a coil protection diode should be used.
Otherwise the signal output could be destroyed by the excess
voltage generated by switching the inductive load off.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
Technical data B0060191 / Rev. 1.7
12
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2.2 Versions of the control unit I20
The control unit article key is coded as follows:
Control unit I20 with optocoupler interface and Fieldbus interface
all sensors are directly connected at the control unit by pluggable contacts.
I20-2-xx-S-FP
A Type of unit I20
B Number of sensors
2 4 up to 2 sensors
up to 4 sensors
C Fieldbus code XX Bus code
D Connection S Cables pluggable
A B C D E
E Enclosure FP Front panel mounting
xx Bus code
PR Profibus-DP
CN ControlNet
DN DeviceNet (B-coded)
DNT DeviceNet (A-coded)
IN Interbus-S
PN ProfiNet IO
CP CanOpen
CC CC-Link
EN EtherNet/IP
ET EtherCAT
Based on the article key shown above, the following versions are available:
I20-2-xx-S
Data backup via fieldbus
or serial USB interface
Control unit for wall mounting, connection of up to 2 sensors,
Fieldbus interface
I20-4-xx-S
Control unit for wall mounting, connection of up to 4 sensors,
Fieldbus interface
I20-2-xx-S-FP
Control unit for front panel mounting, connection of up to 2 sensors,
Fieldbus interface
I20-4-xx-S-FP
Control unit for front panel mounting, connection of up to 4 sensors,
Fieldbus interface
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Technical data
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2.3 Sensors
The sensor description has the following code:
IS20-30GS
A B C D E
A: Inductive sensor
B: S = transmitter, E = receiver
C: Diameter of sensor head
D: Thread
E: Quick disconnect
2.3.1 Sensor pair IS20-30GS / IE20-30GS
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
at nom. sensor distance (min. / max.)
20 (10 – 40) mm
20 (10 – 40) mm
20 (10 – 40) mm
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
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
at nom. sensor distance (min. / max.)
40 (20 – 80) mm
40 (20 – 80) mm
40 (20 – 80) mm
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 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.
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
at nom. sensor distance (min. / max.)
40 (20 – 80) mm
40 (20 – 80) mm
40 (20 – 80) mm
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.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
Technical data B0060191 / Rev. 1.7
14
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2.3.4 Sensor pair ISQ160S / IEQ160S
Technical data
Application:
Part inspection, Material inspection, Hardness inspection
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
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 Schema_Ax.wmf
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.
A
x
Blech
Shee
t
Note The stated measurement ranges are only valid for systems in „Standard“
setting. For details refer to chapter 3.2.
Note The stated measurement ranges are only valid for systems in „Standard“
setting. For details refer to chapter 3.2.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Technical data
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Ax diagrams for sensors IS / IE20-30GS
Fig. 2: Sensor diagrams for sensors IS / IE20-30GS
Note The stated measurement ranges are only valid for systems in „Standard“
setting. For details refer to chapter 3.2.
Ax diagrams for sensors IS / IE42-30GS and ISQ / IEQ42S
30
20
10
0
1
0,05
234
Ax /
mm
STEEL
Ax (2 n)
Ax (n)
A
x (½ n)
40
30
20
10
0
1
0,05
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ax / mm
ALUMINUM
Ax (2 n)
Ax (n)
A
x (½ n)
40
30
20
10
0
1
0,2
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ax / mm
Sheet thickness / mm
STAINLESS STEEL (Austenitic)
Ax (2 n)
Ax (n)
A
x (½ n)
Sheet thickness / mm
Sheet thickness / mm
Ax(n) = nominal sensor gap
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
Technical data B0060191 / Rev. 1.7
16
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Fig. 3: Sensor diagrams for sensors IS / IE42-30GS / ISQ / IEQ42S
Note The stated measurement ranges are only valid for systems in „Standard“
setting. For details refer to chapter 3.2.
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%.
80
60
40
20
0
20,15 46 8
Ax / mm
STEEL
135 7
Ax (2 n)
Ax (n)
A
x (½ n
)
80
60
40
20
0
1
0,1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ax / mm
ALU MINU M
70
50
30
Ax (2 n)
Ax (n)
A
x (½ n
)
80
60
40
20
0
1
0,4
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ax / mm
30
50
70
Ax (2 n)
Ax (n)
A
x (½ n
)
Sheet thickness / m
m
Sheet thickness / m
m
She et th ickn ess / mm
Ax(n) = nominal sensor gap
STAINL ESS ST EEL (Aust e nit ic)
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Technical data
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2.4 Dimensions of the sensors
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
Technical data B0060191 / Rev. 1.7
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Fig. 4: Dimensions of IS/IE sensors
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:
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
Note The sensor cable is an active component of the sensor technology.
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.
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 connected cable) are used,
this cable must be used for extending the sensor cable.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
Technical data
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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.
The volume of accessories depends on the
version of the control unit.
It is shown in Chapter 5.2
“Configuration of connectors“.
Fig. 6: Accessories, packaged
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
System description B0060191 / Rev. 1.7
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Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
System description
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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)
• one pair of sensor cables
3.1 Measurement principle
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“).
3.2 System type
With the system parameter “System type“ the function of the I20 can be fundamentally changed.
Possible choices:
a) Standard
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.
b) FE + AL 0.5 - 3 mm
c) FE + AL 0.1 - 0,8 mm
d) FE + Austenit 0.1 - 1 mm
f) FE + Austenit 0.5 - 3 mm
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!)
g) Frequency
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)
h) Damping mode
Within the system parameter „System type - Standard“ there will be no errorfree 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“.
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.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
System description B0060191 / Rev. 1.7
22
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
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°).
Drawing with 0° and with 90°
Fig. 7: Drawing 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.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
System description
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
23
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
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
System description B0060191 / Rev. 1.7
24
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
From this some simple rules can be derived, which 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 Tea ch-In has to be done with the same sheets (Thickness, material and contour)
used when measuring.
• Adjus t 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
• Fieldbus interface for the control, operation and data exchange with the PLC
• 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
• Optocoupler for direct I/O control via the PLC for fast measurement operations
• Software firmware update
• Data backup via fieldbus interface or USB interface
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
System description
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25
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.
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 production-related
variations 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.
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.
The damping mode is a special application.
For details refer to chapter 3.2.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
System description B0060191 / Rev. 1.7
26
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
“Display value in…“
Switches the indication of the thickness values on the display between mm inch.
“Bus readout value“
Switches the outfeeding of the thickness values via Field bus between mm inch.
“Display time”
Specifies the holding time for the screen display.
Value range 0.0…2 seconds.
“Bus address“
Sets the bus address, as far as a participant address is required for Field bus.
Value range 1…125
“Baud rate Fieldbus“
Sets the Baud rate of the Fieldbus (if required).
In case of EtherNet/IP: DHCP/IP/SUBNET/GATEWAY
“CLR parameter (Clear Program Parameter)“
Deletes all program parameters and all Teach-In data. 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 TeachIn data will be deleted. Using this function only makes sense if a unit is to be newly used for
another machine.
“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 pairs of sensors can be connected, at a 4-channel system I20-4 max.
4 pairs of 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.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
System description
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
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“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. See also 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.
“External Measurement start“
The signal “Measurement start“ can be linked via 3 opto coupler inputs (Measuring start input
1,2,3). Possible configurations:
• IN0 (default setting)
• IN0 and IN1
• IN0 and IN1 and IN2
„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).
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
System description B0060191 / Rev. 1.7
28
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“IN / OUT PLC voltage”
Monitores the external 24V voltage from the PLC.
If “monitoring” is set and the PLC voltage is not connected, an error condition is detected therefore.
“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.
„MAC ID“
Display of the MAC ID for Profinet Bus systems.
“IN/OUT Busproc. data“
Display of the Bus process data. Helpful during commissioning with Fieldbus connected.
“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.
Identifies the control unit.
This information need to be at hand for telephone support.
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
B0060191 / Rev. 1.7
System description
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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.
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
Fig. 9: Visualization of switching thresholds
2
1
0
Signal
Obere Schaltschwelle
Upper switching threshold
Untere Schaltschwelle
Lower switching threshold
a
b
c
Manual
Double Sheet Detector R1000-series I20
with integrated fieldbus interface
System description B0060191 / Rev. 1.7
30
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
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.
See also chapter 3.7.2.
“Teach-In 1-sheet“
Teach-In calibration must 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.
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.
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