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Manual

Double Sheet Detector R1000 series UDK20

B0048991 / Rev. 1.3

System description

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

System description

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Flexible manufacturing systems in sheet metal processing require automated and reliable double

sheet control systems in order to safeguard presses and other processing machinery against

damage due to multiple sheets. This applies not only to steel but also to aluminium and other non-

ferrous metals as well as non-magnetic stainless-steel (austenite), materials as they are

increasingly being used in automotive applications. In addition, the production of so-called

“Tailor Welded Blanks“ (TWB) has created complex manufacturing systems with special

requirements regarding automated double sheet control systems.
The Double Sheet Detector UDK20 was specifically developed for this technical environment. The

special feature of the system is the ability to monitor ferrous and non-ferrous materials with one

sensor only - the PW42AGS.
A system for one measuring point consists of the following three components:

•

Control unit

•

Sensor PW42AGS for ferrous and non-ferrous materials

•

Sensor cable

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3.1

Measurement principle

The Double Sheet Detector UDK20 combines the electromagnetic and eddy current measurement

principles. It monitors the sheet thickness from one side only and in the case of steel does exert

forces only during measurement. A change of the sheet thickness causes a change of the

inductance. The control unit calculates the sheet thickness resulting from this change. Based on

the predetermined thresholds 0-sheet, 1-sheet, or 2-sheets of output signals are generated.

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Summary of Contents for udk20

Page 1: ...different sheet thicknesses and materials Calibration with a teach in procedure Digital display of sheet thickness and operational parameters Monitoring of over gauge and under gauge limits Monitoring of operating voltage and sensor Galvanically insulated 9 bit PLC input interface Galvanically insulated 4 bit PLC output interface Selectable equipment interfaces Data communication and data backup v...

Page 2: ...urer 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 ...

Page 3: ...or data for non ferrous FE material 18 2 6 Sensor cables 18 3 System description 21 3 1 Measurement principle 21 3 2 General hints for process security 22 3 3 Control unit 23 3 4 Parameters of the control unit 23 3 5 Application samples 28 4 Mounting 33 4 1 General mounting instructions 33 4 2 Dimensions of the system 34 4 3 Mounting of sensors 38 4 4 Automatic tool changer 51 5 Electrical install...

Page 4: ...of the Sensor Switch Box 102 9 2 Fault concerning memory 103 9 3 Faults concerning Zero adjust 103 9 4 Faults concerning Teach In 104 9 5 Faults concerning RS232 Transmission 104 9 6 Faults concerning measuring operation 104 9 7 Faults concerning keyboard 104 9 8 Faults concerning supply voltage 105 9 9 Faults Sensor Switch Box 105 9 10 Faults concerning PLC parallel inputs 105 9 11 Other faults 1...

Page 5: ...8991 Rev 1 3 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 5 12 5 Cable plugs and cable sockets 112 12 6 Other accessories 112 13 Appendix 113 13 1 System configuration form 113 ...

Page 6: ...ECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Pos 1 Komponenten allgemein Leerseite 0 mod_1165223317234_501 doc 2343 1 Blank page Pos 2 Komponenten allgemein EG Konformitätserklärung 115 230V AC 0 mod_1173707333875_501 doc 3827 1 ...

Page 7: ...listed below Applied Directives 2006 95 EG Directive regarding electrical equipment to be used within specified voltage levels EN61010 1 2001 2004 108 EU Generic emission standard EN61000 6 2 2005 EN61000 6 4 2001 Date of mark s apposition 01 08 2009 Keltern 01 08 2009 Managing Director Place Date Signature Function of the signer The declaration confirms the compliance with the cited directives Ho...

Page 8: ...000 series UDK20 B0048991 Rev 1 3 8 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 4 Kapitelübersicht 01 Sicherheitshinweise 0 mod_1121421059859_501 doc 505 1 1 ...

Page 9: ...t 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 wit...

Page 10: ...quire 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 UDK20 was specifically developed for this technical environment Depending on the application type of material thickness sensor gap the UDK 20 can be used with up to four sensors The reliable function of the Double She...

Page 11: ...L x W x H Front panel enclosure Protection category IP40 inside IP65 front cover Dimensions approx 180 180 70 mm L x W x H approx 7 1 7 1 3 inch L x W x H Additional characteristics 255 parameter sets memory Programming via pushbuttons 9 potential free optocoupler inputs 24 VDC with joint common Specification min switching voltage HIGH 13 VDC max switching voltage HIGH 30 VDC min switching voltage...

Page 12: ...7236 9392 33 RS232 interface Specification Baudrate 4800 Data Bits 8 Parity Bit None Stop Bit 1 Hardware Handshake None The selection of the interface parameters with the exception of the baudrate is made via the software and cannot be changed by user Pos 11 Doppelblech Geräte UDK20 2 Technische Daten Varianten des Auswertegerätes UDK20 1 mod_1306408103874_501 doc 9239 2 1 ...

Page 13: ...onnectors on the unit pluggable F Control unit in front panel enclosure Version B Memory for 255 parameter sets Nominal thickness and upper and lower limits Set up and addressing by push buttons or via 9 resp 11 opto coupled data inputs 24 VDC with joint common Version C Same as Version B but in addition 1 opto coupled RS232 interface for bi directional data communication with a PLC or PC Basing o...

Page 14: ...42AGS PW42AGS Techn Daten 1 mod_1306414151237_501 doc 9269 3 1 2 3 1 Sensor PW42AGS PW42AGS PW42AGS PW42AGS with straight cable plug with 90 angled cable plug Top View All dimensions are in mm Length tolerance 0 8 mm all other dimensions 0 2 mm Fig 2 Sensor PW42AGS Technical data Measuring range 2 0 2 4 0 mm 01 16 inch Ambient temperature 0 60 C 30 140 F Class of protection IP65 Weight ca 0 5 kg 1...

Page 15: ...e maximum response time corresponds to the maximum sheet thickness Example 1 System parameter Measure fast Measurement with one sensor Nominal thickness 1 0 mm 100 upper limit UP 120 1 2 mm Actual sheet thickness 1 mm actual response time 58 ms Actual sheet thickness 2 x 1 mm actual response time 62 ms Actual sheet thickness 7 x 1 mm sensor on stack actual response time 62 ms The maximum response ...

Page 16: ...e of the system with regard to air gaps between the sheets and increase the systems reaction time according to the diagram Air gaps influence the performance negatively because air has in contrast to steel a high resistance to the magnetic flux Therefore air gaps reduce the performance of the system considerably see chapter 3 1 Measuring principle and conditions influencing measurement accuray For...

Page 17: ... gap between sensor and first sheet 1st air gap 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 2 8 3 0 Sheet thickness mm 1st air gap mm 1 1 2 3 4 5 6 7 0 5 1 5 2 5 3 5 4 5 5 5 6 5 PW42AGS Max air gap between first and second sheet 2nd air gap 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 0 5 1 5 2 5 3 5 4 5 5 5 6 5 2nd air gap mm Sheet thickness mm 2 PW42AGS The data apply for a set upper limit of 120 ...

Page 18: ...ts with 1 sensor as well as for measurements with 2 sensors in sequencer mode Material Conductivity MS Max thickness for single sheet mm Austenite 1 41 4 0 Bronze 8 5 4 0 Zinc 16 3 4 0 AL Alloy 18 2 4 0 AL Alloy 25 2 4 0 AL 34 2 4 0 CU Alloy 43 3 5 CU 57 5 3 0 Pos 15 Doppelblech Geräte UDK20 Bus 2 Technische Daten Sensorkabel 1 mod_1306408102468_501 doc 9233 2333 1 2 6 Sensor cables Suitable cable...

Page 19: ...able socket Bootlace ferrules pink red black violet blue brown white brown green 1 2 3 4 5 6 8 7 9 PW42AGS 1 2 3 4 5 6 8 7 9 1 2 3 4 5 6 8 7 9 1 2 3 4 5 6 8 7 9 1 grey 2 pink 3 red 4 black violet 5 blue 6 brown 1 mm 8 white 1 mm 7 brown 9 green Enclosure blank Shield Cable types for the sensor PW42AGS order data SCPWS GG straight receptacle at the sensor SCPWS GW right angle receptacle at the sens...

Page 20: ...ensor Switch Box to unit Cable socket Cable plug 2 3 5 4 51 22 22 2 3 5 4 1 white 2 green 3 brown 4 yellow 5 grey Enclosure blank Shield 1 white 2 green 3 brown 4 yellow 5 grey Enclosure blank Shield to Sensor Switch Box to unit Cable socket Cable plug 1 2 3 4 5 grey white brown green yellow SSBUDK10 1 2 3 5 4 1 2 3 5 4 1 white 2 green 3 brown 4 yellow 5 grey Enclosure blank Shield Cable type for ...

Page 21: ...ble sheet control systems The Double Sheet Detector UDK20 was specifically developed for this technical environment The special feature of the system is the ability to monitor ferrous and non ferrous materials with one sensor only the PW42AGS A system for one measuring point consists of the following three components Control unit Sensor PW42AGS for ferrous and non ferrous materials Sensor cable Po...

Page 22: ...on of a double sheet detector the air gap between sensor and material surface the magnetical characteristics of the material the tolerance in material thickness From this some simple rules derive which enable a large degree of process security when abided by Always care for good contact of the sensor with the material Use separate programs to measure different sheet thickness and alloy Adjust the ...

Page 23: ...rs of the control unit The UDK20 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 on commissioning and will then remain unchanged Program parameters contain items which are material and job depending and enable individual adaptation to the measurin...

Page 24: ...formation 2 sheet is released If normal is selected the measuring will be executed to the end and the measured thickness will be displayed FE T limit On teaching in of FE material the deviation of the measured thickness from the nominal thickness will be monitored Certain ferromagnetic materials show larger deviations as usual In these cases the 33 142 setting makes sense Default setting is 66 125...

Page 25: ...el Sets the output voltages for outputs 0 1 2 sheet Default setting is 0 V DC Diagnosis factor Diagnosis of the factors located during the Teach In No default setting W Diagnosis Diagnosis of the measuring values for NF material type No default setting UDK20 x x S FP or UDK20 2PW x x S FP SW xx HW xx Identification of unit Need to be at hand for telephone support Version Factory setting Do not cha...

Page 26: ...sor switch box SSB UDK10 the selected sensor must be entered Material Selects the material type FE NF or LM slightly magnetical stainless steels In case of unknown material AUTO must be chosen For all settings except for FE a Teach In is required Nominal measure Changes the nominal measure It can be shown in mm or inch Default setting either 0 03mm or 0 001 inch TO and TU Changes the limit values ...

Page 27: ...ical problem is solved 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 can be zero adjusted separately or all in one stroke The zero adjustment is valid for all programs Teach In Initiates a Teach In via keyboard Teach In is required...

Page 28: ...cription B0048991 Rev 1 3 28 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 3 5 Application samples The following are two typical application examples for the use of the UDK20 UDK20 x x S with one Sensor ...

Page 29: ...Box SSBUDK10 and four PW42AGS Sensors CHANNEL 1 2 3 4 ROLAND ELECTRONIC SENSOR SWITCH BOX SSB UDK10 Attention Using the Sensor Switch Box is only possible in combination with the UDK20 x x S FP but not with the UDK20 2PW x x S FP The optional Sensor Switch Box SSB permits connecting of max four sensors PW42AGS to one UDK20 x x S FP These sensors cannot be operated parallel via SSB but only sequent...

Page 30: ... ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 UDK20 2PW x x S with two PW42AGS Sensors The switching of the sensors can be made as follows a with the so called sequencer mode automatic switching by the unit b by program switching ...

Page 31: ...sensors is predetermined in the program Advantage Very fast measurements are possible smaller software effort on the PLC side Disadvantage There is only 1 summary output for the active sensors available For the summary output the following priorities apply 2 sheet prior to 0 sheet and 0 sheet prior to 1 sheet For details refer to chapter 6 2 1 Program Thickness Sensor 1 1 5 mm 1 2 PLC 1 Measuring ...

Page 32: ...nges 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 Disadvantage A Long time is required for switching the program via the parallel interface 0 7 mm 1 0 mm Program Thickness Sensor 1 1 0 mm 1 2 0 7 mm 2 PLC 1 Select programm 1 2 Measuring programm 1 3 Analysis res...

Page 33: ...ing 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 ...

Page 34: ...49 0 7236 9392 0 Fax 49 0 7236 9392 33 4 2 Dimensions of the system 4 2 1 System in industrial enclosure Version UDK20 for one sensor 125 mm 180 mm 205 mm 140 mm Mounting holes for screws M4 RS232 Sensor SSB central plug 80 mm 132 mm M16 M20 All dimensions are in mm Tolerance 0 2 mm Fig 6 Dimensions of the wall mount enclosure connection view ...

Page 35: ...DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 35 Version UDK20 2PW for up to two sensors 125 mm 180 mm 205 mm 140 mm RS232 Sensor 1 Sensor 2 80 mm Mounting holes for screws M4 central plug 132 mm M16 M20 All dimensions are in mm Tolerance 0 2 mm Fig 7 Dimensions of the wall mount enclosure front view ...

Page 36: ... 9392 33 4 2 2 System with enclosure for front panel mounting identically for one and two sensors Note For connecting the cables an installation space of min 120mm depth must be provided see illustration on next page 4 x Ø 4 2 for Philips head screw M4 DIN 74 180 160 180 160 All dimensions are in mm Tolerance 0 2 mm Fig 8 Dimensions of the front panel enclosure front view ...

Page 37: ... 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 37 Lateral view 130 25 4 105 120 50 Mounting Space All dimensions are in mm Tolerance 0 2 mm Fig 9 Dimensions of the front panel enclosure lateral view Pos 27 Doppelblech Geräte UDK20 Bus 4 Montage Sensormontage 1 mod_1306764362176_501 doc 9380 2 1 ...

Page 38: ...ult in unreliable operations The UDK20 can detect unintentional air gaps The lower limit low should be used for this purpose The lower limit should be adjusted to more than 80 An air gap causes a decrease of the measured value As soon as the measured value falls below the under gauge threshold then under gauge is signalled at the 0 sheet output It is absolutely necessary that the control unit stop...

Page 39: ...xcess lifting suction cups This avoids unnecessary wear of sensor contact surface Pos 29 Doppelblech Sensoren Sensorhalterungen Sensorhalterung SH42GS 1 mod_1306913461859_501 doc 9403 3 1 4 3 2 Spring loaded sensor bracket P sensors should always be fitted into spring mounted sensor bracket rather than rigid mounting arrangements A substantial advantage is in the fact that the sensor present itsel...

Page 40: ... parts 2395117 Spring Kit 2395110 Rubber lips 2395109 Rubber pressure pad 2395117 Spring Kit 2395045 Bellow suction cup Application Characteristics For vertical destackers For robot destackers and high speed linear destackers For inclined sheet stacks o Suction delay time no 0 1 s 0 5 s Note For narrow she ets and applications where weight is critical Strong hold on even sheets due to suction cup ...

Page 41: ...2 33 41 4 3 2 1 Spring loaded sensor bracket SH42GS 6 6 A 57 Hub max 65 min 25 98 10Ø View in direction A without sensor ø20 5 3 0 O 50 110 80 45 1 2 0 75 40 90 Sensor movable fixed All Dimensions are in mm Tolerance 0 4 mm Fig 11 Spring loaded sensor bracket SH42GS Pos 30 Doppelblech Sensoren Sensorhalterungen Sensorhalterung SHS42GS 1 mod_1306912336671_501 doc 9393 344 1 ...

Page 42: ...e or in inclined sheet to the sensor leading to instability of measurement The forces acting in this process can lead to wear and tear to the bracket and lips of the suction cups Generating and releasing vacuum requires considerably longer time The suction cups are not designed to lift and carry the sheet In order to prevent inadvertently the sensor losing touch to the sheet it is necessary to mai...

Page 43: ...tions no turning motions For usage with robotic destackers the sensor bracket SHS42G FB with bellow suction cup is to be preferred Clamping bracket SHK 110 Spring loaded sensor bracket Sensor 6 5 6 ø25 25 94 M8 Rubber nipples Sensor edge Sensor Suction cup A 40 300 or custom made 98 40 Connection 1 4 View in direction A without clamping bracket ø20 5 3 0 O 50 110 80 45 1 2 0 75 40 90 see fig Sprin...

Page 44: ...ut required Fixing of sensor by lateral headless screw with plastic pressure pad Fix the sensor holder by using at least 2 of the M8 tap holes in the mounting plate If required use a ball clamp mount of 28 32 mm for Omni directional adjustment to the sheet surface e g Norgren Co Springer Co Lubricate the sensor thread very sparingly Screwing the sensor from above until the sensor face is positione...

Page 45: ...5210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 45 Fig 15 Base plate for sensor holder SHX42 Replacing the gasket Pull the rubber disc over the lower edge Pay attention for undamaged sealing lips at the inner and outer edge as well as for uniform projection of the sealing edge The gasket can be bilaterally used ...

Page 46: ...ern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 4 3 4 1 Clamping bracket SHX AZ2 25 For fixing the sensor bracket SHX42 to swivel arms with 25 mm clamp collar Fig 16 Clamping bracket SHX AZ2 25 Pos 32 Doppelblech Sensoren Sensorhalterungen Gefederte Sensorhalterung SHS42G FB mit Faltenbalgsauger 1 mod_1215005514906_501 doc 6410 3 1 ...

Page 47: ...rder suction cups with a Shore hardness of 60 black are available see chapter 12 Order data sensors and accessories On installing attention must be paid that the sensor is thoroughly sealed e g with Teflon tape in the thread seating Considerations The sensor face must align with the naps The vacuum must adequately effect The suction facility must be kept free from loading i e the springs may only ...

Page 48: ...92 33 4 3 6 Clamping bracket SHK The clamping bracket SHK can be used for the mounting of the spring loaded sensor brackets SHS GS or SH GS 25 94 M20 M8 21 40 9 5 3 9 5 or custom made 5 5 All Dimensions are in mm Tolerance 0 2 mm Fig 18 Clamping bracket SHK Pos 34 Doppelblech Geräte UDK20 Bus 4 Montage Fehlerhafter Einbau der PW Sensoren 1 mod_1306915442943_501 doc 9409 3 1 ...

Page 49: ...oes not sit perpendicular on the sheet the sensor bracket is apparently not suitable Faulty An air gap exists between the first and the second sheet The sensor is mounted in an unfavourable position Faulty An air gap exists between the first and the second sheet The second sheet clings to the first sheet perhaps by stamping residuals Faulty Fault prone control in a bucket An air gap exists between...

Page 50: ...erence potential e g power supply cable This applies especially to longer cable lengths Pos 36 Doppelblech Sensoren Sensor Switch Box Sensor Switch Box SSBUDK10 1 mod_1306916014366_501 doc 9421 3 1 4 3 9 Mounting of the Sensor Switch Box SSBUDK10 Note The Sensor Switch Box SSBUDK10 should be installed in locations where no vibration exists and no additional heat is transferred into the system even...

Page 51: ...must be suited for peak currents of 2 ampere The shielding of the cable must not be interrupted and therefore have its own contact The contacts must be protected from contamination Do not route the cable together with other cables leading high currents Die metallic parts of the tooling have to be grounded It is not allowed to open the connector during the measuring operation After each tool change...

Page 52: ...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 Pos 41 Doppelblech Ge...

Page 53: ...Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 53 UDK20 x x S FP as front plate mount A Central connector front plate mount terminal strips for direct connection B Connector for RS232 interface C Connector for sensor D Connector for sensor switch box UDK20 2PW x x S in industrial enclosure ...

Page 54: ...92 0 Fax 49 0 7236 9392 33 UDK20 2PW x x S FP as front plate mount A Central connector front plate mount terminal strips for direct connection B Connector for RS232 interface C1 Connector for sensor 1 C2 Connector for sensor 2 Pos 42 Doppelblech Geräte UDK20 5 Elektrische Installation Anschluss Sensor Box RS232 Zentralstecker 1 mod_1309873068863_501 doc 9444 33333444 1 ...

Page 55: ...e cable SCPWS GG or SCPWS GW 2 3 4 5 6 8 7 9 23 24 25 26 22 19 20 27 28 grey pink red black violet blue brown white brown green UDK20 1 2 3 4 5 6 8 7 9 Sensor PW42AGS Sensor plug 1 mm Sensor cable pin Meaning Colour of wire Terminal no of control unit Pin 1 W In 1 grey 23 Pin 2 W In 2 pink 24 Pin 3 12 VDC red 19 Pin 4 0 VDC black black violet in sensor cable 20 Pin 5 12 VDC blue 22 Pin 6 P line 1 ...

Page 56: ...x x S FP Connection of the sensor to the control unit with the cable SCPWS GG or SCPWS GW 2 3 4 5 6 8 7 9 grey pink red black violet blue brown white brown green UDK20 1 2 3 4 5 6 8 7 9 Sensor PW42AGS 43 44 40 41 42 47 48 45 46 Sensor plug 1 mm Sensor cable pin Meaning Colour of wire Terminal no of control unit Pin 1 W In 1 grey 43 Pin 2 W In 2 pink 44 Pin 3 12 VDC red 40 Pin 4 0 VDC black black v...

Page 57: ... versions UDK20 x x S FP but not at unit versions UDK20 2PW x x S FP Connection of the sensor to the Sensor Switch Box with the cable SVCPWS SSBUDK10 1 2 3 4 5 1 2 3 4 5 Sensor Switch Box SSBUDK10 29 30 31 32 33 grey white brown green yellow Sensor cable pin Meaning Colour of wire Terminal no of control unit Pin 1 Switching over signal 1 white 29 Pin 2 Switching over signal 2 green 30 Pin 3 Contro...

Page 58: ...he scope of supply Connections at control unit Manufacturer types notes M8 3 pin female connector at control unit Binder type 768 and others pin 1 GND pin 2 RXD pin 3 TXD RS232 3 View plug side Shield ground Internal at enclosure common Cable SM8KRS232D9S RXD 2 TXD 3 5 3 2 1 2 3 4 5 6 7 8 9 Kabellänge 3 m Cable length 3m X 3 X shield connection at cable receptacle Fig 21 Cable SM8KRS232D9S Warning...

Page 59: ...C2 C3 C4 C5 C6 C7 C8 C9 Fig 22 Central plug 5 2 5 1 Connection to Machine grounding The control unit must be connected to the central machine grounding by a cable with a cross section of at least 1 5 mm Attention The positive supply voltage 24 VDC should not be connected to machine ground 5 2 5 2 Supply voltage cable The voltage supply cable should be kept short Up to 20 m length use cable leads w...

Page 60: ...t 5 Teach In Enable 2 sheet 1 sheet 0 sheet Shield LiYCY 15 x 0 25 mm max 250 VAC 1A Out 0 Enable Out 1 2 sheet Out 2 1 sheet Out 3 0 sheet A1 A2 A3 A4 A5 A6 A7 A8 A9 C1 C2 C3 C4 C5 C6 C7 C8 C9 B2 B3 B4 B5 B6 B7 B8 external power supply 24 VDC 0 VDC 8 5 6 7 38 37 36 35 4 9 10 12 14 16 17 18 34 IN0 IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 24 VDC 0 VDC PLC COM UDK20 Measurement Start Meas menue select Zero a...

Page 61: ...W 0 8 V HIGH 13 30 V Bit 6 A8 IN7 LOW 0 8 V HIGH 13 30 V Bit 7 B8 IN8 LOW 0 8 V HIGH 13 30 V PLC COM A9 Common 0 VDC Data outputs PLC Central plug PLC Central plug Function Pin no Input Specification Relay contact closed if ENABLE active unit o k C1 C2 OUT0 OUT0 max 250 VAC max 1 A Relay contact open if 2 sheet is detected C3 C4 OUT1 OUT1 max 250 VAC max 1 A Relay contact open if 1 sheet is detect...

Page 62: ...n Enable 2 sheet 1 sheet 0 sheet Shield LiYCY 15 x 0 25 mm max 250 VAC 1A Out 0 Enable Out 1 2 sheet Out 2 1 sheet Out 3 0 sheet A1 A2 A3 A4 A5 A6 A7 A8 A9 C1 C2 C3 C4 C5 C6 C7 C8 C9 B2 B3 B4 B5 B6 B7 B8 external power supply 24 VDC 0 VDC 8 5 6 7 38 37 36 35 4 9 10 12 14 16 17 18 34 IN0 IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 24 VDC 0 VDC PLC COM UDK20 Measurement Start Meas menue select Zero adjust Centr...

Page 63: ...GH 13 30 V Bit 7 B8 IN8 LOW 0 8 V HIGH 13 30 V PLC COM A9 Common 0 VDC Data outputs PLC Central plug PLC Central plug Function Pin no Input Specification Relay contact closed if ENABLE active unit o k C1 C2 OUT0 OUT0 Relay contact open if 2 sheet is detected C3 C4 OUT1 OUT1 Relay contact open if 1 sheet is detected C5 C6 OUT2 OUT2 Relay contact open if 0 sheet is detected C7 C8 OUT3 OUT3 C9 Output...

Page 64: ...o SCPWS GW 90 angle socket Superflex C Y PURKOMBI 2 x 1 0 mm 4 x 2 x 0 25 mm 1a Cable plug 9 contacts Order no 2277004 Pin 1 grey Pin 2 pink Pin 3 red Pin 4 black Pin 5 blue Pin 6 brown 1 mm Pin 7 brown Pin 8 white 1 mm Pin 9 green Enclosure blank Shield 1b Cable socket 9 contacts Order no 2276005 straight 2276007 90 angle 1 1b 1a 1 1b Optionale Trennstelle Pin 1 grey Pin 2 pink Pin 3 red Pin 4 bl...

Page 65: ... x 1 0 mm 4 x 2 x 0 25 mm 1a Cable plug 9 contacts 2a Cable plug 5 contacts Order no 2277004 Order no 2277010 Pin 1 grey Pin 2 pink Pin 3 red Pin 4 black Pin 5 blue Pin 6 brown 1 mm Pin 7 brown Pin 8 white 1 mm Pin 9 green Enclosure blank Shield Pin 1 white Pin 2 green Pin 3 brown Pin 4 yellow Pin 5 grey Enclosure blank Shield 1b Cable socket 9 contacts 2b Cable socket 5 contacts Order no 2276005 ...

Page 66: ... 0 25 mm 1a Cable plug 9 contacts Order no 2277004 Pin 1 grey Pin 2 pink Pin 3 red Pin 4 black Pin 5 blue Pin 6 brown 1 mm Pin 7 brown Pin 8 white 1 mm Pin 9 green Enclosure blank Shield 1b Cable socket 9 contacts Order no 2276005 straight 2276007 90 angle 1 1b 1a 1 1b Optionale Trennstelle Pin 1 grey Pin 2 pink Pin 3 red Pin 4 black Pin 5 blue Pin 6 brown 1 mm Pin 7 brown Pin 8 white 1 mm Pin 9 g...

Page 67: ...e br own 1 mm w hite 1 mm br own gr een gr ey pink r ed black blue br own 1 mm w hite 1 mm br own gr een grey pink red black blue brown 1 mm white 1 mm brown green gr een w hite 1 mm br own br own 1 mm blue gr ey pink r ed black X1 X3 X4 X5 und X6 Meaning Colour of wire Pin 1 W In 1 grey Pin 2 W In 2 pink Pin 3 12 VDC red Pin 4 0 VDC black black violet in sensor cable Pin 5 12 VDC blue Pin 6 P lin...

Page 68: ...1_501 doc 9489 2233233344333 1 6 1 PLC inputs For external control parallel PLC inputs are available These inputs can be operated via a PLC If several functions are executed at the same time then the unit issues an fault message The following functions are possible Measurement Start Stop System test Menu selection Teach In not active as factory adjustment Zero adjust not active as factory adjustme...

Page 69: ...sheet 0 sheet 1 sheet 0 sheet 0 sheet 2 sheet 2 sheet 1 sheet 0 sheet 0 sheet 1 sheet 1 sheet 1 sheet 1 sheet 2 sheet 2 sheet 2 sheet 0 sheet 2 sheet 2 sheet 1 sheet 2 sheet 2 sheet 2 sheet 2 sheet 6 2 2 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 6 3 Timing diagra...

Page 70: ...peration otherwise there is a fault condition Before initiating the system test all inputs must be LOW for 30 ms No sheet must be in front of the sensor Switch the input IN5 System test to HIGH All outputs have switched to LOW within 30 ms Switch the input IN5 System test to LOW The unit now performs an internal system test After a maximum time of 100 ms all outputs have switched to HIGH If the co...

Page 71: ...to NF for different sensors SSB 30ms 60ms 60ms Check whether the output OUT0 Enable has switched to HIGH ready for operation otherwise there is a fault condition Before selecting a measurement program all inputs must be LOW for 30 ms Switch the input IN0 Menu selection to HIGH Simultaneously with or delayed switch the binary values to IN1 8 Within 60 ms after switching IN0 Menu selection the outpu...

Page 72: ... must be LOW for more than 30 ms Switch input IN0 Menu selection and simultaneously the binary value to IN1 8 Check after more than 60 ms whether the outputs OUT1 3 have switched to LOW Switch the input IN0 and the binary value IN1 8 to LOW Wait the necessary time refer to the diagram until the outputs OUT1 3 have switched back to HIGH Program no Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1 0...

Page 73: ...time required by the unit in order to issue the result to the output after the signal Measurement Start has been recognized For details refer to chapter 2 4 Note In the relay output version the status of the outputs appears delayed 10 ms due to the switching time of the relays Note High Level at the outputs means relay closed respectively opto coupler low resistant Low Level at the outputs means r...

Page 74: ...lable after the system reaction time ts at the outputs OUT1 3 it remains frozen until the new action is initiated Example with fast PLC BUS cycle time 20 ms Check whether the output OUT0 Enable has switched to HIGH All inputs must be LOW for more then 30 ms After that switch input IN1 Measurement Start to HIGH Check whether all outputs OUT1 3 switch to HIGH within 30 ms After that switch input IN1...

Page 75: ... is initiated IN1 Enable 1 30ms 2 OUT3 OUT2 IN2 8 Meas Start 0 sheet 3 4 1 sheet 2 sheet 30ms 5 30ms OUT1 7 t s t p t s 6 Note In the relay output version the status of the outputs appears delayed 10 ms due to the switching time of the relays Note High Level at the outputs means relay closed respectively opto coupler low resistant Low Level at the outputs means relay open respectively opto coupler...

Page 76: ...puts OUT1 3 The measurement result is frozen until a new cycle is initiated Example with fast PLC BUS cycle time 20 ms Check whether the output OUT0 Enable has switched to HIGH All inputs must be LOW for more then 30 ms Then switch input IN1 Measurement Start to HIGH Check whether all outputs OUT1 3 switch to HIGH within 30 ms Continue to interrogate the outputs OUT1 3 until after the systems reac...

Page 77: ...her the output OUT0 Enable has switched to HIGH ready for operation otherwise there is a fault condition Before initiating zero adjust all inputs must be LOW for 30 ms No sheet must be in front of the sensor Switch the input IN3 Zero adjust to HIGH Within 30 ms the outputs OUT1 3 have switched to LOW After point or 30 ms after point switch the input IN3 Zero adjust to LOW Now the unit performs a z...

Page 78: ...sheet IN0 1 3 8 IN2 Check whether the output OUT0 Enable has switched to HIGH ready for operation otherwise there is a fault condition Before initiating the Teach In all inputs must be LOW for 30 ms One sheet of nominal thickness must be placed in front of the sensor Switch the input IN2 Teach In to HIGH Within 30 ms the outputs OUT1 3 have switched to LOW After point or 30 ms after point switch t...

Page 79: ...al sheets from destacker After the measure again Attention During the removal operation measurement should be switched off because of potentially undefined conditions air gaps between sensor and sheet etc 1 sheet continue with point 7 7 Transport sheet into the proper loading position 8 Measurement to verify that the sensor is still on the sheet 9 Release the sheet 10 After de stacking a sheet per...

Page 80: ... described in the following sections After applying power to the system the system type and the version number are briefly displayed Afterwards the system switches into that measurement menu which was active before the unit was switched off 1 LED functions 2 Pushbutton functions 3 Program number 4 Selected sensor 5 Type of material 6 Nominal thickness 7 Measurement status 8 Lower limit value 9 Sen...

Page 81: ...tion Program Parameter 7 6 Parameter of the respective measurement programs Data backup 7 8 Backup of the data stored in the system via RS232 Interface Fig 28 Main structure of configuration menu 7 3 2 Sub structure Program parameter Auto NF FE LM slightly magn NF off all missing on without ok separate Material Program Parameter Program no 1 255 Sensor number Nominal thickness 0 03 4 mm 0 001 0 15...

Page 82: ...0 V active 24 V active conductivity conductivity range 1 2 3 4 at SSB 1 4 at 2PW 1 2 normal Clear Program Parameter Version HW V UDK20 XX XXX SW V XXX FE T Limit 33 142 nominal value teach faktor thickness range thickness with AD value frequency gain FE Measurement Language Sensor type Number of sensors Dimension Measuring mode CLR Parameter Password external adjust Output level 0 1 2 sheet W Diag...

Page 83: ...1 7 5 Changing setting up or checking the configuration In order to select set up or check the system program parameters press the MENU key The following menu is shown Fig 31 Indication after calling up the menu This menu option permits either reviewing or changing the configuration Configuration review The system program parameters cannot be changed The measurement mode is not interrupted Configu...

Page 84: ... the menu level then the program changes to the measurement mode Pos 56 Doppelblech Geräte UDK20 Bus 7 Inbetriebnahme Parameter Programm 2 mod_1314017995590_501 doc 9922 2 1 7 6 Program parameters 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 Pr...

Page 85: ...material mag NF LM low magnetic material Program parameter 4 Setting the nominal thickness of the sheet to be measured Fig 37 Setting the nominal thickness Value range 0 03 mm to 4 mm 001 inch to 0 157 inch Program parameter 5 Setting the percentage threshold of the upper limit value Fig 38 Setting the upper limit Value range 100 to 150 At the same time the absolute limit value is displayed Progra...

Page 86: ...ually each sensor is addressed individually for yes or no Common All sensors are zero adjusted at the same time In any case the zero adjust continues with the following message requesting to remove the sheet Fig 41 Removing sheet for zero adjust After having the sheet removed press the ENTER key Then the following message appears during the zero adjust Fig 42 Display during zero adjust Note Fault ...

Page 87: ...cuted or if a Teach In has to be repeated the menu option on has to be selected Then the following two messages appears in succession Fig 45 Removing sheet for Teach In Fig 46 Attaching a sheet for Teach In Now a sheet with the nominal thickness must be presented to the sensor Attention A sheet must be attached to the sensor without air gap The position of the sheet during Teach In must be the sam...

Page 88: ...ch In measurement value This measured value can be accepted or changed e g to calibrate the control unit After the Teach In has been completed the following message appears Fig 49 Teach In successfully completed Attention For sequence 1 2 the Teach In is separately performed for sensor 1 and 2 Entering the information for the selected measuring program is now completed program par 8 Teach In ok pr...

Page 89: ... a 66 125 possible upward correction of the displayed thickness max 150 of the indicated value but not more than 125 of the set nominal thickness but not more than the max measurable thickness depending on sensor 4mm for PW42AGS possible downward correction of the displayed thickness min 80 of the indicated value but not less than 66 of the set nominal thickness b 33 142 possible upward correction...

Page 90: ...and confirm with ENTER System parameter 1 Setting the dialogue language Fig 50 Selecting the dialogue language System parameter 2 Specifying the type of sensor Fig 51 Specifying the type of sensor Currently only the type of sensor PW42A is selectable System parameter 3 Specifying the number of connected sensors Fig 52 Specifying the number of sensors Possible choices for 2PW unit 1 2 sensors for S...

Page 91: ... The hints in chapter 6 1 3 1 timing diagram single measurement must be abided by Demo mode This mode of operation is intended for equipment demonstrations but not for the normal process operation The system executes measurements continuously For FE material the repetition time of the measurement is 1 second for NF and LM it is less than 0 085 seconds System parameter 6 Selecting the speed of meas...

Page 92: ...ult 66 125 setting is useful Both values represent the permitted relative range from measured to nominal thickness If the measuring value is not within this range the Teach In cannot be performed and will be aborted with an error message System parameter 8 Deleting all measuring programs Fig 57 Deleting of measuring programs Attention The deletion cannot be undone System parameter 9 Switching the ...

Page 93: ...nd the wiring diagrams 24 V The outputs 0 sheet 1 sheet and 2 sheet 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 System parameter 12 Equipment diagnostics Teach In factors Fig 61 Diagnostics factor The ENTER key leads to the following menu item Fig 62 Indicating the investigated conductance H...

Page 94: ...nu item Fig 64 Indicating the factor for the program investigated on Teach In Here the factor 2PW units both factors for this program investigated on Teach In is shown here prog 12 With the ENTER key and UP DOWN keys all programs can be polled indicated The ENTER key will exit the section The UP key leads to the following menu item Fig 65 Exiting the factor diagnosis section The ENTER key will exi...

Page 95: ...g menu item Fig 68 Setting the thickness range for the diagnosis Here the thickness range for the diagnosis is set With the ENTER key and UP DOWN keys all ranges can be selected The ENTER key will exit the section The UP key leads to the following menu item Fig 69 Indicating the thickness calculated from the characteristic curve Here the value of the analog digital converter and the thickness calc...

Page 96: ...sis section System parameter Indication of Type of unit Software and Hardware Fig 73 Indication of Type of unit Software and Hardware Code UDK20 Type of unit 2 2 sensors connected 2PW Version with 2 sensors SW Software version B Version B HW Hardware version O Version Opto coupler System parameter 14 Indication of system version Fig 74 Indication of the system version This factory setting must not...

Page 97: ...for the system configuration and the parameter sets This is performed via the RS232 interface only for C versions The secured data can be tranfered to spare units in case of exchange after a failure The data backup is accomplished with the RPP XP software available from ROLAND for WinXP The procedure can be selected in the menu configuration The following menu is displayed during the data backup F...

Page 98: ...the following sections 1 LED functions 2 Pushbutton functions 3 Program number 4 Selected sensor 5 Type of material 6 Nominal thickness 7 Measurement status 8 Lower limit value 9 Sensor number with measured value 10 Upper limit value Fig 76 Frontal view of the R1000 with enlarged display detail LED functions symbols above the keys ON if the measured value reaches or falls short of the lower limit ...

Page 99: ...y at the control unit Clear fault and error messages see to chapter 9 Fault messages causes and remedies Teaching of new types of metal and sheet metal thicknesses see section 7 6 Configuration of program parameters Clearing a 2 sheet condition in preparation The following notes for measuring operations should be observed Note If the measured value fluctuates and deviates substantially from nomina...

Page 100: ...face Confirm with ENTER key Attention The sheet used for the teaching process must have the same sheet thickness and same electrical conductivity in case of non magnetic metal e g aluminium as the sheet to be processed 16 The control unit shows the measured thickness in the display General rules for monitoring ferrous material steel that can be magnetized and non ferrous materials aluminium non ma...

Page 101: ...ault message The fault number indicates the fault and the probable cause The fault description and the suitable measures to remedy the fault condition are found in the following tables The cause of malfunction must be eliminated before the equipment can continue operation The fault can be cleared by pressing the MENU key on the control unit Note As long as the cause of the fault is not eliminated ...

Page 102: ...yed Fig 78 System does not recognize a Sensor Switch Box After pressing the MENU key the following message is displayed Fig 79 Selection if the Sensor Switch Box is to be operated Adjustment for operating the Sensor Switch Box yes The equipment should continue operating with a Sensor Switch Box The fault is cleared If the fault condition is not eliminated then the fault message appears again no CL...

Page 103: ... parameter Output 0 1 2 is out of range 18 System parameter External adjustment is not realistic 19 System parameter FE measurement is not realistic The memory errors 3 to 19 except error 7 can be redressed as follows Select the defective system parameter in the system configuration Press the ENTER key the corresponding setting will the blink Correct the value with the Arrow keys Store the value w...

Page 104: ...he defined range e g Program no 255 Repeat data transmission with correct values 47 The serial commands are following too fast Include a small pause between the individual serial values 48 A serial function was started although another serial function was still active Await completion of the active serial function then restart the serial transmission 49 The command is not known Check command 9 6 F...

Page 105: ...rallel function is not possible because another parallel function is active e g measurement start and in addition Teach In 1 sheet See timing diagrams 72 Selected program number 255 Select the new program number 73 Parallel function is blocked in the system configuration ext adjust no If required change configuration 76 The parallel function is not possible because the system was configured to int...

Page 106: ...icherungen 1 mod_1310642349010_501 doc 9640 222 1 10 1 Replacement of sensors Warning When connecting or disconnecting the sensor plug you must stop measurement Non observance can result in a damage of the sensor In order to further use the taught programs the following must be observed Before the sensor is removed its installation position must be exactly documented This applies especially to the...

Page 107: ...e sensor resp the sensors 6 Switch to zero adjust and confirm with the ENTER key 7 Select zero adjust separate or zero adjust common 7 1 If zero adjust separate then confirm with ENTER key 7 1 1 Display zero adjust S1 on remove sheet If zero adjusts desired then ENTER key or if zero adjusts not desired then activate off and confirm with ENTER 7 1 2 Display zero adjust S2 off If zero adjusts not de...

Page 108: ... this form is not available or filled out the information on the system configuration must be retrieved from the equipment documentation 10 3 Replacement of fuses Attention The fuse should be checked only by trained personnel since it is necessary to open the control unit The power supply fuse is 5 x 20 mm 3 15 Amp slow blow A spare fuse is accommodated in the control unit The position of the spar...

Page 109: ...fective control unit this backup can be transferred to another control unit The instructions of the programs can be accessed via the help function after installation pdf Hardware requirements C version of a ROLAND unit series R1000 such as E10 E20 I10 UDK10 UDK20 or Fieldbus units PC with Windows 95 98 2000 NT XP Vista 7 installed and a free serial interface or USB set at COM1 COM10 null modem cab...

Page 110: ...s as the UDK10 e g UDK10 B R UDK20 B R The terminal blocks are pin compatible Cables can be re used The previously used sensor PW42GS must be replaced by a sensor PW42AGS Controlling the unit via the PLC is identical The response times of the UDK20 are substantially shorter than those of the UDK10 see chapter 2 2 Sensor data It must be ensured that the power supply is capable to supply max 60W for...

Page 111: ...ta backup UDK20 C O S FP unit with one sensor or SSB Same as UDK20 C O S but control unit in front panel enclosure UDK20 2PW B R S Control unit in wall mount enclosure memory for 255 parameter sets programming and operation via keys 9 potential free data inputs 24 VDC with joint common relay outputs UDK20 2PW B R S FP Same as UDK20 2PW B R S but control unit in front panel enclosure UDK20 2PW B O ...

Page 112: ... Spare rubber pad black for sensor bracket SHS42G FB 2395109 Spare rubber pad for suction cup SP42GS and for sensor bracket SHS42GS and SHX42 2395110 Spare rubber lips for sensor bracket SHS42 and SHX42 or suction cup SP42 12 4 Cables Order information Specification Description SCPWS GG Superflex C Y PURKOMBI 2 x 1 mm 4 x 2 x 0 25 mm Cable for connecting sensor PW42AGS to UDK20 or to SSBUDK10 both...

Page 113: ... System configuration form Standard settings are printed bold deviations are marked Language D E I S F Sensor type PW42AGS Number of sensors 1 2 3 4 Dimensions mm inch Measuring mode demo external single external continuous FE Teach Limit 66 125 33 142 FE Measuring normal fast Password yes no Level 0 1 2 0 VDC 24 VDC External adjust yes no Unit version _________________ Pos 80 Komponenten allgemei...

Page 114: ...Manual Double Sheet Detector R1000 series UDK20 B0048991 Rev 1 3 114 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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