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DoubleSense Model III User Manual

1. White is active when 1 The sensor detects a missing layer e g one 1 sheet out of 2 missing This can for example be used as a warning that the sensor was calibrated on a double sheet 2 The sensor is not calibrated Example The diagram below displays the Layer Error output signal position when the sensor calibrated on a double sheet Note that the signal for a missing layer will appear after the first paper after calibration i e the second paper in total and on every following paper Calibration a Detection Layer Error Output 13 ms 15 ms Diagram 17 Signal scheme for Layer error output signal The Layer Error signal will appear 13 milliseconds after the paper trail edge 6 2 4 Paper Present output 04 The Paper Present Output O4 Grey is active when paper is present between the sender and receiver i e from the lead edge to the trail edge The Paper Present indication can be used by the machine control system in several ways 1 To count the number of paper sheets 2 To register when a paper is in the sensor i e at position A positive flank to B negative flank 3 To detect the paper passing time i e the time between positive and negative flank 4 To detect missing sheets i e IF NOT Paper Present THEN Missed sheet alternative to using the Trig Input and the Stop Error Output for missing sheets The diagram below shows the Paper Present Output active The output has a 4 ms filter for lea
2. all errors 2 Paper Present 3 Operation Mode When the sensor is configured for pulsed outputs see chapter 7 2 4 Error output duration and more than one error occurs the output signal for the first error will be pulsed 15 or 40 ms before the next error is shown 6 4 Serial communication The sensor unit is prepared for handling serial data communication This can be done in two different ways RS422 half duplex RS485 full duplex The communication protocol will be implemented in co operation with each machine manufacturer in order to optimise functionality When serial communication is used and more than 8 addresses are needed the 8 pin DIP switch can provide some additional addressing Contact Svensk Elektronikproduktion for information 46 0 300 70 000 Sensor configuration This chapter will provide you with information about how to change the signalling time of the outputs how to trig the detection at a certain spot on the paper and more Note 1 Before any configuration can be made the power has to be turned OFF otherwise the electronics may be damaged CAL amp ND Note 2 Please take ESD Electrostatic Sensitive Devices precautions when touching the electronics Note 3 The sensor only reads the new DIP switch settings when the calibration routine is initiated 7 1 DIP switch overview Two DIP switches are located inside the processing unit Access the DIP switches th
3. Sender and receiver not properly aligned DIP switch settings incorrect Hardware error RAM memory Hardware error DA converter Hardware error EEPROM The sensor continues to check for another 3 sec before indication is turned off Check the DIP switch settings Sensor defect or damaged Sensor defect or damaged Sensor defect or damaged Diagram 9 Power up error indication table Contact Svensk Elektronikproduktion if the sensor indicates hardware error 46 0 300 70 000 DoubleSense Detection Features This chapter describes What information the user can get from DoubleSense III Definitions of what is meant by each information e g a double sheet a missed sheet or a layer error Short description of how the sensor indicates the different situations and how they are displayed A detailed table overview of LED indications is found in chapter 8 Input and output functions are found in chapter 5 and 6 3 1 Double sheet A double sheet is defined as the paper being twice as thick or twice as dark as the calibrated sheet A double sheet can consequently be more than 4 sheets if the sensor was calibrated on 2 sheets more than 8 sheets if the sensor was calibrated on 4 sheets etc When a double sheet passes the sensor the infrared receiver receives approximately half of the light compared to the light it received during the calibration The light reduction values opacity
4. Setting the sensor in Calibration mode Achieve Calibration mode by activating the Calibration Input for at least 15 ms The Calibration mode can also be set by using the CAL key on the sensor operator panel 2 Setting the sensor in No Double mode when the sensor does not detect double sheets Achieve No Double mode by activating the Calibration Input for more than 2 seconds 22 sec 5 3 Reset Input The Reset Input 13 Yellow has two basic functions 1 Toreset deactivate the error outputs Pulse the Reset Input for 15 ms to reset active error 2 Toturn the sensor OFF or ON Activate the Reset Input for more than 2 seconds 5 4 Halt Input The Halt input 14 Green is used when the paper repeatedly is brought to a stand still in the machine The Halt Input must be activated in order to interrupt the sensor detection sequence Paper stand still is only allowed during paper detection if the Halt Input is activated Note 1 In case the sensor does not receive information about paper stand still it will not perform a correct double detection Note 2 Paper stand still is only allowed during detection and not during calibration If the paper has been in between the sender and receiver for more than five seconds the sensor will indicate an error 5 5 Signal requirements The signal requirements for each input must be thoroughly followed by the installer If the signal requirements are not fulfilled the sensor will n
5. The sender and receiver lens housing is partly threaded 28 mm and delivered with an M8 nut a washer and an O ring attached The units can for example be clenched mounted on a U shaped or a key hole cut out The cable must not be bent to any side since it might effect the throughbeam capacity Keep the cable straight no bending angle for at least 5 centimetres from the lens housing Do not pull or twist the cables See chapter 2 3 2 for alignment check at installation Svensk Elektronikproduktion AB Page 7 43 2 14 Dimensions processing unit The following diagram shows the mechanical dimensions of the processing unit 80 4 mm 26 0 mm 94 mm Front view Top view 358mm Diagram 4 Dimensional drawing processing unit 2 15 Mounting instructions processing unit The processing unit can be mounted on the outside of the machine to facilitate direct access to the sensor operator panel or inside an electrical cabinet as a unit integrated with the machine control system When placed out of reach for direct operation the sensor can be controlled via inputs outputs or serial communication The processing unit consists of sensitive electronic components Please mount the unit steadily in a vibration free environment All cable connectors have a security pull latch
6. are processed in an algorithm to evaluate whether the reduced light is caused by the variations in the printed colours or by a real double sheet The indications for double sheets are 1 LED 2 indicates DOUBLE RED 2 Stop Error Output or Logic I O s are active see chapter 6 for details 3 2 Paper Jam Paper Jam is defined as the presence of a paper in the sensor when it is expected NOT to be there In this situation it is possible that paper is stuck jammed or overlapped by another paper The sensor detects a Paper Jam when Trig Input is deactivated and a paper is still in between the sender and the receiver The following indications are made for paper jam 1 LED 2 indicates Paper Jam GREEN 2 Stop Error Output or Logic I O s are active see chapter 6 for details Note The user must provide the sensor with an input signal in order for the sensor to know during what time to expect a paper between the sender and receiver To use this function a selection must be made on the DIP switch See chapter 5 and chapter 7 Svensk Elektronikproduktion AB Page 13 43 3 3 Missed sheet A missed sheet is defined as the absence of a sheet in the paper feeding process The Trig Input on the sensor must be activated to inform the sensor when a sheet is expected to appear between the sender and the receiver If no paper is found to be present when Trig Input is activated the following indications will be giv
7. V 250 mA The inputs are active at Config Inputs active Inputs inactive PNP gt 0 8 x Up 0 5 x U NPN lt 0 2x Up gt 0 5x Up Svensk Elektronikproduktion AB Page 9 43 PNP DS3 INTERNAL CONNECTIONS RELAY Transient suppression os diode 1N4148 or equal OUTPUT e D DIODE INPUT T SWITCH INPUT o le POWER SOURCE a DC UPV H 5 6 Diagram 6 Connection diagram PNP DS3 INTERNAL CONNECTIONS RELAY Transient suppression o diode 1N4148 or equal ke OUTPUT i C DIODE INPUT SWITCH INPUT e o o POWER SOURCE DCUpV 5 Diagram 7 Connection diagram NPN 2 2 4 Additional sensor configuration In order to adjust the sensor for specific machine conditions a number of sensor configurations are available e g NPN PNP signal duration etc Configurations can be made on the two DIP switches located on the circuit board inside the processing unit Access the DIP switches through the plastic plug on the processing unit Set the switches carefully with the help of a small screw driver pencil or other sharp pointing object Find detailed description of the configurations in chapter 7 Access to DIP switch O 9 ee eee Diagram 8 DIP switch access 2 3 Power up The sensor is automatically powered up when the power supply is turned ON Precaution The power supply s
8. between the sender and receiver ERROR 1 Green Other Error Hold down the ERR key on the sensor operator panel to display the error type at hand Go to Error Sub Menu APPENDIX 2 and read the error LED 4 m OFF 1 No Paper in between the sender and receiver COM 2 No serial communication PAPER 1 Red Serial communication the sensor is communicating via the serial interface 1 Green Paper Present the sensor has detected a paper in between the sender and receiver The LED is ON for as long as the paper is present APPENDIX 2 Sub Error Menu LED Indication Error Action must collect more specific data This can take up to 4 papers LED 2 1 Red Too dark too thick paper Switch the sensor to No Double mode by pressing the ND key The calibrated paper is too thick or too for more than 2 seconds or dark for the infrared light to beam activating the Calibration Input through for more than 2 seconds The sensor will only detect LED3 1 Red missed sheets paper jam and time errors in this mode LED2 YFlashing Calibration incomplete extended 1 Press RES Red calibration required 2 Run 1 4 more papers LED 3 1 Red Paper print is complicated and the sensor completely through the Sensor 3 Calibration is finished when LED 1 indicates Detection mode otherwise press ND and enter No Double mode LED 2 1 Red Total passing time too long during The sensor does not allow paper cali
9. has indicated Too thick too dark paper the sensor can be switched to No Double Mode 1 Manually switch the sensor to No Double Mode by pressing the ND key on the sensor processing unit for more than 2 seconds 2 Alternative Automatically set the sensor to No Double Mode by activating the Calibration Input 12 for more than 2 seconds Inputs This chapter describes the four inputs on DoubleSense and the signal requirements for each input Note that all inputs and outputs do not necessarily have to be used However in some applications the sensor requires certain signal inputs in order to perform functions selected on the DIP switches The inputs and outputs are located in the 8 pole modular connector I O connector see chapter 2 Installation The duration of the inputs and outputs can be set on the DIP switch see chapter 7 Name Position Wire colour Function Trig Input 1 Brown Starts detection sampling when activated Calibration Input 2 Blue 1 Sets sensor in Calibration mode when activated pulsed gt 15 ms 2 Sets the sensor in No Double mode when activated more than 2 sec Reset Input 3 Yellow 1 Resets latest error on positive flank 2 Turns the sensor OFF when activated more than 2 sec Halt Input 4 Green Stops halts sampling during paper stand still Used if paper stand still is necessary Note For all inputs 2 ms positive flank filter 10 ms end flank filt
10. printed paper reduces approximately seven times as much light as a white paper The thickness of the paper DoubleSense can handle white paper less than 20 g m e g bible paper up to one white carton 1000 g m The level of transparency of the material If a completely transparent sheet is put in the sensor the infrared light will not be reduced i e all of the light will go through the material like sunlight through a window and detection is not possible However a faintly coloured sheet e g plastic material will reduce the light to some extent and detection may be possible The number of layers in the paper set e g how many sheets the sensor has to consider as being a single sheet Folded sheets disperse the infra red light more than one much thicker carton does Each layer disperses the light to a certain angle and that angle is consequently increased with each layer until the light is reduced to zero The distance between folded sheets If the sheets in a folded paper set are not tightly pressed together the light is dispersed through each layer and reduced so much that the receiver receives little or no light at all The distance between the sender and the receiver For optimal beam through capacity the sender should be mounted aligned with the receiver at a distance from lens to lens of 10 25 mm The distance from the paper surface to the receiver should be 0 5 mm Stray light directed towards the receiver may be mistaken for
11. sensor trigs on the lead edge of the paper and starts sampling automatically DIP 2 OFF 2 External Trig The sensor starts sampling only when the Trig Input 11 is activated sampling trigged by positive flank DIP 2 ON Note External Trig is necessary in order for the sensor to be able to deliver an output signal for Miss sheet and Paper Jam If the configuration is not made the sensor will not recognise the Trig input 7 2 3 External trig signal duration DIP switch three 3 has two functions depending on the setting of DIP switch two 2 1 If DIP 2 is set to Automatic trig DIP 2 OFF then DIP 3 sets the paper edge delay i e the time it takes for the entire light beam area to enter the paper The user can choose between 5 ms edge delay DIP 3 OFF or 25 ms edge delay DIP 3 ON The following situations require a choice on this switch When the feeding speed of an A4 sheet or US Letter is below 0 7 m s then a 25 ms edge delay is recommended DIP 3 ON When the feeding speed of an A4 sheet or US Letter is above 0 7 m s then a 5 ms edge delay is recommended DIP 3 OFF 2 If DIP 2 is set to External trig DIP 2 ON then DIP 3 permits the user to choose between using a pulsed short Trig signal or a long Trig signal Trig held The following situations require a choice on this switch When detecting Missed sheets a pulsed Trig Input signal is enough for the sensor to recognise the
12. At this choice the sensor has a 100 accurate picture of the paper at hand which results in that the reliability of the detection is egually high If an error is found then Error Output is activated after the paper trail edge Paper Sampling whole sheet Error Output oe 13 ms Diagram 21 Error output signal position at Normal Detection At Interval Detection DIP 1 OFF the sensor samples during a 20 ms interval starting from the paper lead edge or from Trig Input and signals status based on samples from this interval only The Error outputs will signal the status directly after this interval The sensor then waits until it detects the trail edge before it is ready to detect again Paper Sampling 13 ms calculation 20 ms se Error Output _ 15 ms_ Diagram 22 Error output signal position at Interval Detection Note The accuracy of the detection is only guaranteed when the paper speed is absolutely constant same speed at calibration and detection If DIP switch eight 8 is set to OFF when DIP switch one 1 is OFF the sensor will operate on a special application mode program that is customer specific Please make sure that DIP 1 and DIP 8 is not set to OFF at the same time Unless special application program is being used 7 2 2 Trig selection DIP switch two 2 permits the user to choose between 1 Automatic Trig default The
13. CIEN NEHME EN NESS ke ee be sd 24 SI daElimi ia M 25 6 C6 LUE ula OE ED De E EN 26 6 1 CHOOSING GROUPED OR LOGIC OUTPUT SIGNALLING eere 26 6 2 GROUPED OUTPUT SIGNALLING eerte rte eene en ene nr ner ue ede eee Rente 26 6 2 1 Stop Error output O1 e 6 2 2 Time Error Output O2 sesse sesse ee or ed ee SA GE ed AG Se oe Ee ee de Re 6 2 3 Layer Error output O3 ss 6 2 4 Paper Present output O4 we 6 3 LOGIC QUTPUT SIGNALLING rieri onito tnter nh RH GER See ERE eR Ye ne GER ee ees d 6 4 SERIAL COMMUNICATION ee ese ee se ee ee ee ee Ge Re Ge ee AR GR EESE DERSE Ge Re ee de ee 7 SENSOR CONFIGURATION een see se n ek RR KERR EER KEER KEER KEER KEER KEER KEER KEER KEER KEER KEER KEER KEER 31 DIP SWITCH OVERVIEW 2 2 petet rE vos REL EP EYE RSG ERG OSSE BEN AG ERR ERE RES ee vend ECT ATE tees Ge Eed 31 7 2 DIP SWITCH CONFIGURATION SETTINGGS cccssscccsssecesssccesseecesssecesseeeesseecesseeeesseeeesseeeees 31 2 2 l Sampling length se EER me RR EDEN see ER MEYER ER Re NE ODER ES 32 7 2 2 Trig selection is 7 2 3 External trig signal d ration iet n menie ni ene ede 7 24 Error Output Duration RE EE EE EE 7 2 5 Selection of output signalling 7 2 6 Selection of COMMUNICATION 7 2 7 Input and output configuration PNP NPN ss 34 7 2 8 High Detection Half duplex Medium Detection Full duplex 34 8 OPERATOR PANEL eene ese en sen knee ke ek K
14. DoubleSense Model III User Manual SVENSKElektronikproduktion AB DoubleSense Model III Detailed User Manual Revision date 11 May 1999 Issued by Pia Fridhill HMS Sensors AB EMC requirements EN 5081 2 EN 5082 2 Valid for program version DS3 pv98 Copyright Svensk Elektronikproduktion AB Svensk Elektronikproduktion AB Energigatan 8 S 434 37 Kungsbacka Sweden Phone 46 0 300 70 000 Fax 46 0 300 711 54 Email info doublesense com Web www doublesense com Table of contents 1 PRODUCT APPLICATION mms 4 Ll SENSOR FUNCTION RE in ESSERE TRETEN CARET etai eines tests ten 5 2 INSTALLATION 6 2 UMECHANICAL CHARACTERISTICS eec ede ee EH GE eg EDU EE RHODE RENE HR OR ER ed 24 T Cable COnfieCtOtS iacere neon ente ee ere E ER PR ex E e y t ess ee 2 1 2 Dimensions sender and receiver nennen enne enne enne 2 1 3 Mounting the Sender and Receiver 2 1 4 Dimensions processing unit 2 1 5 Mounting instructions processing UNIE sesse see see ee ee Ge Re RA ee eene 8 2 2 ELECTRICAL CHARACTERISTICS 9 2 2 1 Power supply 9 2 2 2 I O connector 9 2 2 3 Input and output connection 9 2 2 4 Additional sensor configuration 10 2 3 POWER UP T 2 3 1 Error indications at Power Up 11 2 3 2 Sender and receiver alignment check 11 3 DOUBLESENSE DETECTION FEATURES errem 13 34 DOUBLE SHEET etos IRR IE LR ne Res ee He pere ee
15. EER KEER KEER KEER KEER KERKE EER K NEER NEER KEER KEER KEER dianid RNEER KEER KEER 34 PANEL OVERVIEW seen e HRS RN ERES BY ERR eee Re ERE anse nee 8 2 LED INDICATIONS eoi EE OE EE KOSSE EE EE 8 2 1 Main indications 8 2 2 Sib errordndications EE Dep aD WS MO EN RENTE 8 2 3 Sub Error Operation suse reip nene erred ore eee ei eee Veg en 8 3 ERROR HISTORY SEARCH TOOL n 84 OPERATION KEYS soiin EA EE EE ER RE EE OE EEG FERRO FE APPENDIX 1 MAIN INDICATION MENU iii Re ee ee ee ee ee 37 APPENDIX 2 Sub Error Menu i APPENDIX 3 OPERATION KEYS eee eene eine odore eo N Gee n miedo iaceo eie do Res TECHNICAL SPECIFICATION msn 43 Svensk Elektronikproduktion AB Page 3 43 Product application The DoubleSense III is a double sheet sensor that can be used for detecting double sheets missed sheets paper jam and the presence of a paper passing the sensor Further useable functions are detection of pass time errors and the detection of one missing layer out of two or major paper opacity differences in the paper flow DoubleSense can be used in any type of sheet feeding process e g in enveloping machines where it is extremely important that for example a confidential bank account draft does not end up in the wrong envelope DoubleSense also ensures a higher quality in collating machines foil wrapping machines and print feeders where the sensor checks the sheets at each feeder station Other applications are for example
16. Ge Eg Gee PR REFER ex 3 2 PAPER JAM M 1 3 3 MISSED SHEET ne S L MEAYER ERROR zv ee Ge eek ve ee erp Ge We Ge N ee m IUE 9 9 dd SE n AR EE ER EE EL 3 6 CALIBRATION ERRORS 3 7 PASS TIME ERRORS 35 87 E IS ius GN OER EE eee PH YRE EE EE eon ee erae eroi 16 4 OPERATING THE SENSOR mises 17 4 CALIBRATION MODE EE RE ENEO ERA en tie Ree eR e RENE e eee 4 1 1 How to calibrate DoubleSense y 4 1 2 Save calibration value isi es nett ara I ERR En S REVERSES EEEIEE 4 1 3 Indications during Calibration Mode 4 2 EXTENDED CALIBRATION MODE e 4 2 1 Indications and operation in Extended Calibration 4 2 2 Error indication after Extended Calibration Mode iese esse see ee ee Re Re 19 4 3 DETECTION MODE 4 3 1 Indication in Detection Mode 44 NO DOUBLE MODE NES ere URN nn n Gede ee eke n Ge en ede REEL HERES 4 4 1 Indication in No Double Mode ve 4 4 2 Switching to No Double Mode 5 INPUTS suser nnn nnn nn nn rr ri f Ke AR Ee f 21 Sel ADRIGANPUT ES ES EE EE Ge Ge ce SEMANA 21 25 2 CALIBRATION INPUT cesses eene Gees resecie ES Gee SEE ERGER eN EXC nr Gee ner einer ELCHE EE enr Deeg eres 22 5 3 RESET INPUT x S4 HALT INPUT 54444 64474 EE EE EE na RENS YR HRS RENS RATE EXERCERE dpa 5 5 SIGNAL REQUIREMENTS ek eie bia qe ee Hex eti eed GR Ge ee GN OX M ODE ER PRAE RE RANDE EAE 23 5 5 1 Trig Input oe 3 99 eei o 24 5 5 3 Reset Input x eet i PORTS DNE RE
17. OVIDED THAT THE SAME PAPER IS BEING PROCESSED The Operation Mode LED will turn GREEN immediately after power up sequence to indicate that the sensor is in detection mode i e already calibrated If the paper type i e print pattern colours or paper thickness is changed YOU MUST RE CALIBRATE THE SENSOR Press the CAL key or activate the Calibration Input and follow the Calibration procedure previously described in chapter 4 1 1 4 1 3 Indications during Calibration Mode LED 1 is RED to indicate Calibration Mode When a paper passes through the sensor LED 4 will indicate PAPER GREEN Error indications during calibration mode are too long pass time too short pass time miss sheet paper jam extended calibration and Halt input active during calibration See Indication menus in Appendix 1 and 2 4 2 Extended Calibration Mode If the paper has a complicated print the sensor requires more than one paper to complete the calibration A complicated print can be defined as sharp changes between high and low opacity for example when a smaller area at the lead edge is white and the rest is black Other print changes can also evoke an Extended Calibration Mode In this case the sensor needs to complete the calibration on 1 4 subsequent paper sheets NOTE During the extended calibration sequence double sheets are not detected The operator must make sure that the calibrated sheets are single sheets 4 2 1 Indication
18. ardation is considerably slow compared to the normal speed the sensor will get inaccurate sampling data and will not be able to detect double sheets on a reliable basis I Paper at stand still 0 m s between sender and Halt Input Paper speed 8 ms Diagram 15 Signal scheme for Halt input paper speed Svensk Elektronikproduktion AB Page 25 43 Outputs This chapter describes the four outputs on DoubleSense Note that all outputs do not necessarily have to be used The inputs and outputs are located in the 8 pole modular connector I O connector see chapter 2 Installation The duration of the outputs can be set on the DIP switch see chapter 7 However in this chapter the signalling of the outputs will be shown as 15 ms Choosing Grouped or Logic Output Signalling The input and output signalling can be used in two ways depending on how much information the user requires 1 In the Grouped output signalling Output 1 signals for a group of 8 errors and Output 2 signals for a group of 5 errors Output 3 and 4 each signals for one situation each This system provides the user the choice of connecting only one or a few outputs to the machine system 2 The Logic output signalling is an array of logic combinations providing the user with information on all 16 occurring error types or function modes The array is created by the 4 outputs together Both ways of obtaining i
19. between the sender and the receiver The sensor detects the lead edge and signals until the trail edge The Paper Present detection can be used for Detecting the presence of a paper To count the number of paper sheets To detect the length of the paper in terms of paper passing time i e the time between positive and negative flank To detect missing sheets i e IF NOT Paper Present THEN Missed sheet Paper Present is indicated by 1 LED 4 indicates PAPER GREEN for as long as the paper is present 2 The Paper Present output O4 active from lead edge to trail edge 3 6 Calibration Errors The sensor detects three 4 different calibration errors Paper stand still The paper was present for more than five 5 seconds between the sender and the receiver during calibration Paper passing time too fast The paper passing time was below the minimum of 23 ms from lead edge to trail edge which is insufficient for a successful calibration Paper too dark or too thick An insufficient amount of infrared light was received by the receiver during calibration Extended calibration values needed The paper print was complicated and the sensor needs another 1 4 sheets in order to process the calibration values correctly Halt input activated during calibration The sampling sequence was interrupted during calibration It is not permitted to stop the paper in between the sender and the receiver during calibra
20. bration gt 5 seconds stand still during calibration Recalibrate the sensor by The calibration sampling has lasted more starting the machine and running LED3 m OFF than 5 seconds a paper completely through the sensor at normal speed LED 2 m OFF Total passing time too short Lower the machine speed The sensor needs at least 23 ms sampling or time lead edge to trail edge to collect enough opacity values to detect double Set the sensor to No Double sheets The paper is too short the paper mode by pressing the ND LED3 YFlashing speed is too high or a combination of key The sensor will then Red both only detect missed sheets paper jam and time errors L H Continued on next page Svensk Elektronikproduktion AB Page 39 43 LED Indication LED 2 1 Green LED 3 1 Green LED 2 1 Green LED 3 LED 2 1 Green LED 3 1 Red LED 2 1 Green LED 3 Y Flashing Red Error Missing layer too light paper The sensor possibly calibrated on a double sheet and this sheet was single The paper was of lighter colour than the calibrated paper There was one layer missing out of two Total passing time too long during detection gt 5 seconds The detection sampling has lasted more than 5 seconds Passing time is 10 times longer than during calibration 10 1 1 The paper is 10 times longer that of the calibrated paper the due paper do
21. d edge detection and 4 ms filter for trail edge detection A B Paper Present Output ok x3 Edge filter 4 ms Edge filter 4 n Diagram 18 Signal scheme for Paper Present output signal 6 3 Logic Output signalling The Logic output signalling is an array of logic combinations providing the user with information on all 16 occurring error types and operation modes The 4 outputs create a logic array where each output will have the value of a digital 1 or 0 When combined the errors or states will be indicated 1 Active output 0 Deactive output Signal Output Detection Mode Paper Present Double Off Mode Calibration Mode Layer Error 67 Paper pass time 150 Paper pass time Too dark or too thick paper Pass time 10 1 of calibration pass time 10 Pass time 1 10 of calibration Halt active during calibration 11 gt 5 seconds Maximum pass time exceeded 12 Incomplete calibration continued calibration required 13 23 ms paper edge delay Minimum time error 14 Missed sheet 15 Paper Jam 16 Double sheet Drop ION npe TED ES ooo coooo mM m m m OCC COP RP RP EO OOON AHAOOHHMOOHHOOHHMOOYN Svensk Elektronikproduktion AB Page 29 43 Since the outputs are used for modes and states as well as errors the signals will be active in a certain priority order The signals will be activated according to the following priority 1 Errors
22. data bus information and real time signals simultaneously More information about serial protocols and the use of serial communication will be given on request since such applications are customer specific therefore requiring customised settings 7 2 7 Input and output configuration PN P NPN DIP switch no 7 permits the user to set the output signalling configuration to NPN inputs and outputs active low or PNP inputs and outputs active high The power voltage Us is 12 24 V See chapter 2 2 3 for details The inputs have a resistance load of approx 12 kOhm 7 2 8 High detection accuracy Standard detection accuracy DIP switch no 8 is used for two different settings one when serial communication is used Half or full duplex and one when serial communication is not used High and medium detection When serial communication is NOT used then the user can choose between the following detection principle modes High detection accuracy In this setting the sensor samples over the whole sheet and takes the status decision on three sampling levels The double detection accuracy is 99 8 in this setting DIP switch 8 OFF Standard detection accuracy In this setting the sensor samples over the whole sheet and takes the status decision on an average value of the total opacity variation In this detection setting the accuracy of the decision may be somewhat reduced but the sensor is more tolerant to differenc
23. displays the possible error sources displayed with a combination of RED GREEN flashing RED and flashing GREEN on the two LEDs See diagram 9 page 12 for Power up sub indication menu The sensor can be restarted by holding down CAL and ND simultaneously for more than 2 seconds 2 32 Sender and receiver alignment check At installation check the alignment of the sender and the receiver 1 Hold down the CAL and RES key simultaneously 2 The LED s will perform an alignment check to indicate optimal alignment If all LED s are GREEN the alignment is 98 100 optimal If more than one 1 LED shows RED or OFF then there is dust or misalignment Note All LED s must show GREEN in order to reach optimal sensor performance Please align the sender and the receiver so that all LEDs show GREEN Be careful not to bend the sender and the receiver cables since a sharp bend might effect the alignment Svensk Elektronikproduktion AB Page 11 43 Power up error indication menu D aicatio 9 O O LED 2 YFlashing Ol and O4 Dust or other articles Remove dust or article red active paper in between the hindering the infrared light sender and the receiver j LED3 1 Red 1001 Align sender and receiver LED2 YFlashing No red indication LED3 1 Green LED 2 1 Red No indication LED3 1 Green LED 2 1 Red O1 and O3 active LED 3 YFlashing 1010 red LED 2 1 Red No indication LED 3 YFlashing green
24. ed Error Passing time too long during detection The paper passing time increased with more than 150 from one paper to the following 1 The machine speed dropped 2 The paper was longer than the previous possible paper jam or overlapping papers Passing time too short during detection The paper passing time decreased to less than 67 from one paper to the following 1 The machine speed increased 2 The paper was shorter than the previous wrong paper or damaged paper Halt input activated during calibration Paper stand still is not allowed during calibration only during detection if Halt input is activated Action If Paper Jam remove error and Reset Keep paper passing time within the range 0 67 1 5 times the previous paper If damaged paper remove error and Reset error Keep paper passing time within the range 0 67 1 5 times the previous paper Run the calibration paper completely through the sender and receiver During detection activate the Halt input at paper stand still Svensk Elektronikproduktion AB Page 41 43 APPENDIX 3 Operation Keys The operation panel has four buttons with the following functions Key Duration gt 2 seconds Function Calibration Comment Sets sensor in Calibration mode All errors reseted Outputs and error LED s inactivated gt 2 seconds No Double ND Disables the double and layer d
25. en 1 LED 3 indicates MISS RED 2 Stop Error output or Logic VO is active see Chapter 6 for details Note The user must provide the sensor with an input signal in order for the sensor to know when to expect a paper between the sender and receiver To use this function a selection must be made on the DIP switch See chapter 5 and chapter 7 3 4 Layer error A layer error is defined as one 1 missing layer out of two 2 i e if the sensor calibrated on two layers of paper it will signal when only one layer passes the sensor The missing layer is considered by the sensor as an opacity value that is twice as high as the stored calibration value i e too light paper Consequently if the sensor is calibrated on four 4 layers of paper it will detect if two 2 layers are missing provided that the opacity of each layer is approximately the same This information can be used in three ways As a warning that the calibration was possibly carried out on a double sheet To warn if a paper set is missing one 1 layer out of two 2 To warn if the paper opacity is too light wrong paper compared to the calibrated opacity value The indications for a layer error are 1 First LED 3 indicates ERROR GREEN 2 Second When ERR key is held down LED 2 is GREEN and LED 3 is GREEN the combination for missing layer too light paper 3 Layer Error Output O3 is active 3 5 Paper Present Paper Present is defined as the presence of a paper
26. er Diagram 10 Table overview of sensor inputs 5 1 Trig input The trig input I1 Brown is used when 1 Detecting Paper Jam and Missing Sheets The Trig Input should be activated by the control system when a paper sheet is expected to be present between the sender and receiver DIP switch 2 must be set to ON see chapter 7 If Trig is activated and no sheet is detected by the sensor within 4 ms then Miss sheet error is indicated If Trig is deactivated and paper is found in between the sender and the receiver within 4 ms the sensor indicates Paper Jam error In order to use the Paper Jam detection DIP switch 2 and 3 must be set to ON see chapter 7 2 Starting the detection on a specific position on the paper The sensor starts sampling when Trig is activated on positive flank and ends when the paper trail edge is detected Svensk Elektronikproduktion AB Page 21 43 In order to use the Trig Input a selection must be made on DIP switches 2 and 3 see chapter 7 Application example In a horizontal collator the paper is transported through the sender and receiver by a metallic suction device In this case the sensor would be unable to start detecting the lead edge and sample over the metallic suction device Instead the Trig input starts the sampling directly after the suction device has passed the sender and receiver 5 2 Calibration Input The calibration input 12 Blue is used for 1
27. es between papers DIP switch 8 ON If DIP switch eight 8 is set to OFF when DIP switch one 1 is OFF the sensor will operate on a special application mode program that is customer specific Please make sure that DIP 1 and DIP 8 is not set to OFF at the same time Unless customer specific application program is being used Operator panel This chapter explains the functions of the sensor operator panel When the sensor works as a stand alone unit the operator panel will be the main interface for the user If the sensor is integrated with the machine and operated mainly via inputs outputs or serial communication the operator panel will be a help in error search situations From the operator panel several error types can be displayed and reseted the error history buffer will be displayed and deleted and the sensor can be set to different work modes to mention a few of the possibilities 8 1 Panel Overview The operator panel is placed at the front of the processing unit Each LED can display two 2 colours GREEN and RED A combination of RED GREEN flashing RED flashing GREEN and OFF indicate several error types LED 1 Operation Mode RED Calibration Mode GREEN Detection Mode Teddie Flashing GREEN No Double Mode CAL Calibration MODE Flashing RED Extended Calibration Mode ro DOUBLE LED 2 Error ax JAM RED Double sheet GI ND No Double GREEN Paper Jam ao MISS ERR 3 MI i iss sheet cr
28. es not correspond to the calibrated paper 2 The paper speed has decreased 10 times compared to the speed during calibration or the paper is at a stand still 3 Possible Paper Jam Passing time during detection is 10 of calibration time 1 The paper was at a stand still during calibration and the following papers were run at normal speed 2 The paper had 10 the length that of the calibrated paper the due paper does not correspond to the calibrated paper 3 The paper speed has increased 10 times compared to the speed during calibration Action Recalibrate the sensor on a single sheet The sensor allows stand still during Detection Mode but warns that a stand still effects the detection accuracy if the Halt Input is not used The sensor will still try to continue the detection e Check if the calibrated paper correspond to the latest fed paper Recalibrate the sensor on the right paper Do not stop the paper in between the sender and receiver unless the Halt Input is activated e Check if a Paper Jam has occurred Recalibrate the sensor by starting the machine and running a paper completely through the sensor at normal speed Check if the calibrated paper correspond to the calibrated paper E Continued on next page LED Indication LED 2 YFlashing Green LED 3 1 Red LED 2 YFlashing Green LED 3 YFlashing Red LED 2 1 Red LED 3 YFlashing R
29. etection 1 PAPER LED indication and Paper Output still active but no double sheets or layer errors are detected 2 The sensor only checks for missed sheets paper jam and time errors in ND mode Use when double detection is not wanted or necessary For paper thickness at the ends of the opacity range the sensor can handle The NoDouble mode is also achieved by activating the Calibration Input I2 2 seconds Hold down Shows ERROR indication sub level As long as the ERR key is held down When the ERROR LED is GREEN the ERR key is used to find the due sub error See APPENDIX 2 2 seconds Resets displayed error Resets active outputs and LED s gt 2 seconds gt 2 seconds Resets all errors if more than one has occurred on one paper Alignment test If keys are held down simultaneously the sensor enters a routine where it checks if the sender and receiver are aligned and free from dust The sensor enters calibration mode when CAL amp RES is held down again Resets active outputs and LED s If all LED s are GREEN the alignment is correct If one or more LED s show RED or OFF then there is dust or misalignment 2 seconds ON OFF Inactivates and reactivates the sensor in all modes if pressed simultaneously TECHNICAL SPECIFICATION Paper opacity From coloured plastic sheets or bible paper and up to 1000 g m white cardboard Coloured sheets
30. indicate Detection mode GREEN or No Double mode flashing GREEN when turned on Calibrate the sensor by going through the following steps or follow the quick guide 1 Pressthe CAL key on the sensor or activate the calibration input I2 2 sec The Operation Mode LED turns RED to indicate Press CAL that the sensor is not yet calibrated and that the sensor is ready to calibrate on the next passing sheet 2 Startthe paper feeding sequence in your system and run one paper completely through the sender and the receiver at normal machine speed 0 5 4 5 m s The LED 4 indicates PAPER GREEN as long as the paper passes through Note The sensor does not allow paper stand still during calibration Feed paper through 3 The Operation Mode LED turns GREEN to indicate that the Calibration sensor is now in Detection Mode The calibration has been finished successfully achieved Note If a paper is in between the sender and receiver when the calibration is activated the sensor will start calibration on the next following paper edge or Trig input Svensk Elektronikproduktion AB Page 17 43 4 1 2 Save calibration value When a correct calibration is achieved the values are automatically saved in the internal sensor memory When the sensor is powered up the latest calibration data will be restored and can be used again without re calibrating the sensor The detection process can proceed without a new calibration PR
31. is flashing RED LED 3 is RED LED 3 is RED Press the RES key to reset error indications and outputs Try a new calibration If the sensor fails to calibrate again then the sensor cannot calibrate on the due paper Press the ND key for 2 seconds to start No Double Mode In this mode the sensor does not check for double sheets or layer error but all other errors are still detected 4 3 Detection Mode When the calibration is successfully achieved the sensor will automatically enter the Detection mode During this mode the sensor samples opacity data over the whole sheet on each passing sheet or from Trig input positive flank or during 20 ms depending on DIP switch selections see chapter 7 The data is first processed and then compared to the previously stored calibration data When the processing is finished the sensor signals the status of the due paper sheet In Detection Mode the sensor detects 1 2 3 Double Sheets Missed sheets if Trig is active and selected on the DIP switch see chapter 7 Paper Jam if External Trig and Trig held are selected on the DIP switch see chapter 7 and Trig input is activated Svensk Elektronikproduktion AB Page 19 43 4 The presence of a paper between the sender and the receiver Paper Present 5 Correlation of the paper passing time 6 Missing layer too light paper 4 3 1 Indication in Detection Mode LED lis GREEN to indicate Detection Mode Whe
32. iver Caused by Machine speed retardation paper speed retardation Overlapping papers longer passing time The paper pass time has decreased by more than 33 compared to the previous paper passing time tyresent tprevious X 0 67 This signal is activated after the paper has left the sender and receiver Machine speed acceleration paper speed acceleration Damaged or wrong paper entering the sensor too short torn or ripped paper The paper pass time was below 10 of the time during calibration This signal is activated after the paper has left the sender and receiver Machine speed acceleration 10 times the calibration speed Svensk Elektronikproduktion AB Page 27 43 Damaged or wrong paper entering the sensor 10 times shorter paper torn or ripped 4 The paper pass time was 10 times longer than the calibration pass time This signal is activated while the paper is still present between the sender and receiver Possible paper stand still but shorter than 5 s Wrong paper entering the sensor 10 times longer paper Many overlapping papers in a row 5 Paper pass time longer than 5 seconds during detection This signal is activated while the paper is still present between the sender and receiver Paper stand still not allowed unless Halt input is used to interrupt sampling sequence 6 2 3 Layer Error output 03 The Layer error output O3
33. light from the infra red sender since light bulbs or sunlight also contains frequencies of infra red light Operating the sensor The sensor operates in four work modes Calibration Mode Extended Calibration Mode Detection Mode and No Double Mode The sensor is automatically turned ON at power up If the sensor has been manually turned OFF then turn the sensor ON by pressing the keys CAL and ND on the operator panel for 2 seconds 4 1 Calibration Mode The Operation Mode LED indicates calibration mode when RED and the sensor is thereby ready to calibrate on the next passing sheet In Calibration mode DoubleSense collects opacity data from the paper on a path reaching from the ead edge to the trail edge of the paper default The collected opacity data is processed and stored as an opacity profile to be used as a comparison value in detection sheets If the sensor is configured to use the External Trig the calibration begins at the Trig Input positive flank and ends at the trail edge of the paper If the sensor is configured for Interval Detection 20 ms the calibration starts at the paper edge or at the external trig and ends after 20 ms See chapter 7 Sensor configuration 4 1 1 How to calibrate DoubleSense First make sure that no paper or other article is in between the sender and the receiver before or at power up If the sensor has pre stored calibration values from previous runs the LED 1 will
34. machine can then be adjusted in order to avoid lowered performance due to frequent error sources When a new error occurs and the buffer is full the sensor deletes the oldest error in the buffer Follow the steps below to access Error History 1 If LED 3 shows ERROR hold down the ERR key to display the error 2 The error will be shown on LED 2 and LED 3 Read the error type in the main indication menu APPENDIX 1 or the sub error menu APPENDIX 2 3 Press the RES key shortly to reset the displayed error 4 The next stored error will immediately be displayed Press RES to reset it etc 5 To reset all stored errors at once press RES for more than two 2 seconds Note all stored errors in the Error History will be deleted Note When Grouped Output signalling is used the sensor shows the latest error of maximum eight 8 in the error buffer At RESET the sensor deletes the displayed error and resets all outputs The next error from the buffer is then shown on the LED s but not on the outputs When Logic Output signalling is used the sensor shows the oldest error in the eight 8 error buffer At RESET the sensor deletes the displayed error and resets the corresponding output signal The next error from the buffer is then shown on both the LED s and on the outputs When the error buffer is empty all error outputs are deactivated and error LED s turned off 8 4 Operation keys There are four 4 operation keys o
35. missing sheet DIP 3 OFF When detecting Missed sheets and Paper Jam the Trig Input must be held until after the paper has passed the sensor If the paper is still present in the sensor when the Trig Input is deactivated Paper Jam will be detected DIP 3 ON See chapter 5 Inputs for signal description 124 Error Output Duration DIP switch four 4 permits the user to set the duration of the error outputs 1 Error outputs pulse for 15 or 40 ms to indicate an error DIP 4 ON The choice between 15 or 40 ms output pulse can be made on DIP switch 6 2 Error Outputs are held until Reset Input 3 is activated or until the RES key is pressed DIP 4 OFF See chapter 6 Outputs for signal description 7 2 5 Selection of output signalling At default the sensor is operating on Grouped Output signalling DIP 5 OFF Svensk Elektronikproduktion AB Page 33 43 For the user who wishes to obtain extended information but cannot use the serial interface the Logic Output signalling is an option see Logic Output chapter 6 3 The Logic Output signalling is active when DIP 5 ON See chapter 6 Outputs for more information 7 2 6 Selection of communication If serial communication is used then DIP 6 OFF The outputs will however still be active also when the selection for serial communication is made The serial interface can therefore be used together with the I O s so as to receive
36. n ERROR GREEN Sub Error ERR Error sub menu RES Reset LED 4 Indication RED Serial communication crn PAPER GREEN Paper present e rep COM Fi g amp R 5 3 H E a I OUBLESENSE Diagram 23 Sensor operator panel 8 2 8 2 1 LED Indications Main indications The four LED s have the following functions 1 LED 1 Operation Mode LED indicates which mode the sensor is currently in Calibration mode Detection mode No Double mode and Continued Calibration mode 2 LED 2 and LED 3 Indicate the three most common errors DOUBLE PAPER JAM and MISS For all other errors sub errors the ERROR indication on LED 3 will be turned on When holding down the ERR key the sub error type will be displayed on LED 2 and LED3 3 LED 4 Indication LED shows when serial communication is used COM and when there is a paper between the sender and receiver PAPER The Main indication menu is found in APPENDIX 1 The Sub indication menu is found in APPENDIX 2 Svensk Elektronikproduktion AB Page 35 43 8 2 2 Sub error indications When LED 3 GREEN Hold down ERR key The diagram below shows a principal overview of how the sub error indication works When LED 3 indicates ERROR GREEN a sub error has occurred There are 11 types of sub errors When holding down the ERR key LED 2 and 3 will switch to sub error indication showing a combination of red green flashing red flashing gree
37. n a paper passes through the sensor LED 4 will indicate PAPER GREEN 44 NoDouble Mode The paper is considered too dark or too thick in case an insufficient amount of infrared light reaches the receiver during calibration The sensor must now be switched over to No Double Mode In the No Double mode no doubles are detected but the following situations will continue to be detected 1 Missed sheets if Trig is active and selected on the DIP switch see chapter 7 2 Paper Jam if External Trig and Trig held are selected on the DIP switch see chapter 7 and Trig input is activated 3 The presence of a paper between the sender and the receiver Paper Present 4 Correlation of the paper passing time 4 41 Indication in No Double Mode LED 1 is flashing GREEN to indicate No Double Mode If the sensor detected a too thick or too dark sheet during the calibration sequence or failed to carry out calibration in extended mode the following indication will inform the user about the situation 1 LED3is GREEN to indicate that an error has occurred and the Stop Error Output O1 is activated 2 Access the sub indication menu by holding down the ERR key 3 The sub error indication indicates Too thick too dark paper when e LED2is RED and e LED3is RED Any other combination by LED 2 and LED 3 indicates another error See APPENDIX 2 for a full description of sub indication errors 4 4 2 Switching to No Double Mode When the sub error indication
38. n and Off The Sub Error Indication Menu in APPENDIX 2 displays which type of error has occurred LED 2 and LED 3 OPERATION MODE show Sub Errors by combination of RED GREEN rep DOUBLE flashing RED flashing crn JAM GREEN and OFF rp MISS ERROR rep COM crn PAPER HMS Sensors 46 35 172981 OUBLE ENSE Diagram 24 Sub Error indication and operation 8 2 3 Sub Error Operation When LED 3 indicates ERROR GREEN follow the sequence below 1 Hold down the ERR key on the operator panel The LED s will change and indicate the due sub level error for as long as the ERR key is held down Find the corresponding error in APPENDIX 2 Sub Error Indications Remove the error or change the conditions that caused the ERROR indication Press the RES key to reset each error more than one can occur see chapter 8 3 below or hold the key down for 2 seconds to reset all errors if more than one occurred Continue in Detection Mode with previously saved calibration values no action needed or recalibrate the sensor press CAL key or activate Cal Input 8 3 Error History search tool When errors occur DoubleSense stores them in an internal memory error buffer This function can be used in the adjustment phase during installation and test run Up to eight 8 errors are stored in the sensor memory allowing the user to conclude which errors are most common in the process The
39. n the sensor operator panel Some of the keys have more than one function by touching the key shortly holding it for more than 2 seconds or holding down 2 keys simultaneously The description of the key functions is found in APPENDIX 3 APPENDIX 1 Main Indication Menu LED The main indication menu explains each of the functions of the four LED s one by one Indication Function Svensk Elektronikproduktion AB Page 37 43 m OFF l Power OFF LED 1 2 Start up sequence hardware test at power ON OPERATION 1 Red Calibration mode the sensor is ready to calibrate on the next paper MODE sheet that enters the sensor The sensor has no previously stored calibration values YFlashing Extended Calibration mode the sensor operates in the continued Red calibration sequence for complicated papers 1 Green Detection mode Detection program active calibration values stored YFlashing No Double mode Green The sensor operates in No Double mode i e no double sheets are detected Other errors are still detected LED 2 m OFF No double or jam error detected DOUBLE 1 Red Double sheet the sensor has detected a double sheet JAM 1 Green Paper Jam the sensor has detected a paper jam the paper was still in the sensor after the Trig Input was deactivated LED 3 m OFF No miss or other error detected MISS 1 Red Missed sheet Trig Input was activated and no paper found in
40. nformation are described in this chapter The selection between the two signalling ways is made on DIP switch 5 see chapter 7 Grouped Output signalling The table below presents an overview of the Output functions in the Grouped VO signalling Name Position Wire colour Function Stop Error Output 1 Red Active for Double Miss Paper Jam and four 4 types of calibration errors Time Error Output 2 Black Active for five 5 types of pass time errors during detection Layer Error Output 3 White Active when the paper opacity value is twice as high as the calibrated value e g one missing layer out of two calibration made on double sheet etc Paper Present Output 4 Grey Active when paper is present between the sender and receiver Diagram 16 Table overview of sensor outputs When the sensor is configured for pulsed outputs see chapter 7 2 4 and more than one error occur the sensor will automatically interrupt the first error to show the second one and so on This means that for example error one 1 can be signalled for 4 ms and interrupted by a second error 2 that is shown for 15 ms 6 2 1 Stop Error output 01 Stop Error Output O1 Red is activated after the following seven high priority errors have been detected by the sensor 1 Double Error The sensor detected a double sheet The signal is activated 13 ms after the paper trail edge Miss Error The Trig i
41. nput was active and no paper was found between the sender and receiver Miss error signal is activated 1 ms after Trig input positive flank Note To use the Trig input a selection must be made on the internal DIP switch Paper Jam The Trig input was deactivated and a paper was still between the sender and receiver Note To use the Trig input a selection must be made on the internal DIP switch Paper stand still The paper passing time exceeded 5 seconds gt 5 sec during calibration Too short pass time The paper pass time was below the minimum for calibration lt 23ms paper edge delay see chapter 7 DIP switch settings The sensor did not receive enough samples to create a calibration data Too dark too thick paper The paper was too dark or too thick to beam through Incomplete calibration The paper print was complicated and the sensor needs more calibration data Halt active during calibration The sensor does not allow paper stand still during calibration and neither if the Halt Input I4 is activated during calibration sequence 6 2 2 Time Error Output 02 Time Error Output O2 Black is activated for pass time errors during detection not during calibration The Time error output signals when 1 The paper pass time has increased by more than 50 compared to the previous paper passing time tpresent tprevious X 1 50 This signal is activated while the paper is still present between the sender and rece
42. odular connector have 8 poles whereas the serial modular connector has 4 poles The power connector is of battery eliminator type often used as power connector in battery adaptors Sender 3 pole connector Receiver 4 pole connector Serial connector 4 pole modular 1 0 connector 8 pole modular Power connector circular 1 9 mm M Diagram 2 Connecting to the processing unit 2 1 2 Dimensions sender and receiver DoubleSense has one infrared transmitter sender and one photoelectric receiver that are included in each delivery The cable is shielded and 2 metres long for both sender and receiver 3 pole connector Keep cable straight 5 cm M8 0 75 mm fine thread M8 nut __ N IR Sender L v 10 25 mm 43 amp Paper 0 5 mm IR Receiver 4 pole connector Diagram 3 Dimensions sender and receiver and location relative to paper 2 1 3 Mounting the Sender and Receiver For optimal beam through capacity the sender should be mounted 10 25 mm from the receiver and the paper surface should pass 0 5 mm above the receiver Direct the light beam 90 to the paper surface In order to keep the receiver away from stray light and direct light sources the receiver can be mounted above the sender as well as vice versa
43. ot be able to perform detection with optimal function and reliability and perhaps in some cases not at all This chapter contains signal charts of each of the four inputs 5 5 1 Trig Input The Trig Input can be pulsed or held until after the paper trail edge see chapter 7 Sensor configurations DIP switch 3 The Trig Input can be activated anywhere on the paper The sensor must however receive a satisfactory amount of samples at least 23 ms of paper sampling is required before the trail edge 1 Trig held for miss sheet and paper jam detection Paper Jam Paper Jam Sampling Y Detection Trig Input Diagram 11 Signal scheme for paper jam detection DIP 2 ON DIP 3 ON The Trig Input 12 must be active until well after the paper has passed the sender and receiver If the Trig is deactivated when the paper is still present in the sensor then a Paper Jam error will be indicated 2 Trig pulsed for miss sheet detection min 10 ms Paper 1 Paper 2 Missed sheet Paper 3 Sampling Sampling Trig Input Diagram 12 Signal scheme for miss sheet detection DIP 2 ON DIP 3 OFF The sensor starts sampling at the positive flank and continues until the trail edge of the paper Svensk Elektronikproduktion AB Page 23 43 5 5 2 Calibration Input Function Signal time Calibration 15 ms 2s No Double Mode 22
44. ource must be turned OFF 0 VDC before the power connector is plugged into the processing unit in order to avoid damage At power up power voltage turned on the sensor automatically checks the alignment and function of the sender and the receiver the function of the CPU and other hardware components The power up sequence 1 All LED s first turn RED 1 sec and then GREEN 1 sec 2 If the hardware is functional the Operation Mode LED will start indicating due mode directly after the power up sequence If the sender and the receiver are misaligned or if dust or other articles hinder a sufficient amount of light to reach the receiver the sensor will immediately show an error message see Power up error indication menu on the next page When the error has been removed the sensor will continue for 3 seconds to show the error message before it is turned off To manually turn the sensor ON OFF Press the keys CAL and ND simultaneously for 2 seconds The sensor will not perform the hardware check at manual ON OFF Alternative Activating Input 3 for more than 2 seconds will turn the sensor ON OFF 2 3 1 Error indications at Power Up If the LED s fail to go through the RED GREEN sequence at power up and all LED s are OFF the unit may be damaged If any errors are found at the power up sequence they will immediately be indicated on LED 2 and LED 3 and on the outputs The error indication table diagram 9 on the next page
45. rough the plastic plug at the right side of the operator 1 Communication panel see figure in chapter 2 2 4 terminating switch The DIP switches have the following function 1 Terminating DIP switch 4 pin only used for serial communication 2 8 pin DIP switch for configuration settings 2 Coinguanon Diagram 19 DIP switches 7 2 DIP switch configuration settings This chapter explains the settings at hand when the sensor is using Inputs and Outputs I O only or a combination of I O and serial communication where no further addressing is needed The diagram below shows an overview of the function of each switch on the 8 pin DIP switch Interval Detection 20 ms Normal Detection whole sheet Automatic Trig External Trig Pulsed Trig or 5 ms edge delay Trig held or 25 ms edge delay Error outputs active until Reset Error Outputs pulsed 15 40 ms DIP 6 Grouped Output signalling Logic Output signalling O1 O2 O3 O4 Output pulsed 40 ms Output pulsed 15 ms NPN outputs active low PNP outputs active high High detection accuracy Standard detection accuracy Diagram 20 DIP switch definitions Svensk Elektronikproduktion AB Page 31 43 7 2 1 Sampling length DIP switch one 1 permits the user to choose between Normal Detection and Interval Detection At Normal Detection DIP 1 ON the sensor samples over the entire paper or from the Trig Input positive flank before it indicates the status
46. s Activate the Calibration Input at least 20 ms before the paper lead edge If the Calibration Input is activated when the paper is present between the sender and the receiver the sensor will calibrate on the next following sheet If the Trig Input is used for starting the detection sequence there must be at least 20 ms between the Calibration Input negative flank and the Trig Input positive flank Paper gt 20 ms Calibration Input J oo Diagram 13 Signal scheme for calibration input signal 5 5 3 Reset Input In default configuration Grouped output signalling DIP switch 5 OFF see chapter 7 the reset input immediately resets all outputs when pulsed for at least 15 ms Example Stop Error Output 01 RESET Input 13 or key operation Diagram 14 Signal scheme for reseting outputs When Logic Output signalling is set on DIP switch 5 see chapter 7 then the RESET Input will reset the first error that occurred if more than one occurred in a sequence Immediately after the first error is reset the outputs will show the next error an so on until all errors in the buffer are reset 5 5 4 Halt Input The Halt Input 14 Green stops the sampling sequence for as long as the input is active Activate the Halt input just before the paper speed is at 0 m s and deactivate the Halt Input just before the paper starts accelerating again Note If the acceleration or ret
47. s and operation in Extended Calibration This situation is indicated and handled as follows 1 LED I turns flashing RED to indicate that Extended Calibration Mode is required 2 Stop Error Output O1 or Logic I O is active 3 LED 3 indicates an ERROR GREEN after the first calibration paper has gone through The sub error indication press ERR key shows the indication for incomplete calibration LED 2 is flashing RED and LED 3 is RED Press RES key to reset the error indication and the outputs DO NOT press CAL in this sequence or else the sensor will have to start all over again Feed 1 4 more papers completely through the sensor The sensor will continue the calibration procedure adding calibration values until a satisfactory data processing has been made When the calibration procedure is finished LED 1 will indicate Detection Mode GREEN This can take between 1 and 4 sheets added to the first sheet 4 2 2 Error indication after Extended Calibration Mode If the sensor cannot calibrate on the due paper even after the extended calibration mode sequence the following happens 1 2 3 4 After feeding 1 4 sheets through LED 1 still indicates Calibration Mode RED LED 3 indicates ERROR GREEN Stop Error Output O1 or Logic VO is active Press the ERR key and the sub error indication indicates one of the following errors Too thick too dark paper Incomplete calibration LED 2 is RED LED 2
48. sheet the user will get a warning from the sensor that a possible feeding failure might have occurred Although the material is too thick or too dark for the sensor to beam through the sensor can continue to detect missed sheets paper jam and signal whenever a sheet is present between the sender and receiver Thanks to the advanced data processing DoubleSense can handle sheets with varying print patterns in an accurate way Therefor DoubleSense is not likely to deliver false error signals on black areas unlike many other light sensors used in double detection Neither is DoubleSense very sensitive to height variations i e if the paper flutters or to moist variations such as is the case with some inductive sensors Svensk Elektronikproduktion AB Page 5 43 Installation When installing DoubleSense Model III please follow the instructions in this chapter in chronological order The sensor consists of the following Main processing unit Sender and receiver including cable and cable connector Additional equipment can be ordered from HMS Sensors Power cable with battery eliminator connector I O cable with modular connector Serial cable with modular connector 2 1 Mechanical characteristics 2 11 Cable connectors All cable connectors are polarised and cannot be placed in the wrong connector The sender has a 3 pole connector and the receiver has a 4 pole connector The I O input output m
49. that prevent them from detaching during use Make sure that the connectors are properly fastened to ensure that the pull latch is clenched into the connector Use M3 M4 screws metric system to fasten the processing unit Use washers to avoid that the plastic surface be damaged by the torque load 2 2 Electrical characteristics 2 2 1 Power supply The power connector is a battery eliminator type Connect according to the following Connector Symbol Power U Max Average Min White eS U 12 H 5 600 mA 125 mA 80 mA Black Volt DC 24 5 300 mA 70 mA 40 mA 2 2 2 1 0 connector The inputs and outputs are located in the modular connector 8 pin named I O connector The I O cable connector has the following standard configuration Input 1 Brown Trig Input 2 Blue Calibration Input 3 Yellow Reset r Input 4 Green Halt L Output 1 Red Stop Error Output 2 Black Time error Output 3 White Layer Error Output 4 Grey Paper present Diagram 5 1 0 modular cable connector configuration 2 2 3 Input and output connection The outputs can be configured as PNP or NPN Please restrict voltage for inactive inputs and outputs to between 0 V and U in order not to damage the unit PNP U residual voltage 1 V 150 mA at U 12 V 250 mA at Up 224 V NPN 0 V residual voltage 1
50. the detection of a plastic card or sticker on a letter the detection of web splice pieces in a web offset system or recognition of a correct sheet fold These applications are to a certain extent customer specific and require software adjustments for the due environment Processing unit Wallet size Power Receryer supply 3e Ea cp t Material Am LL Sender Serial cable i i I O cable Control system PC PLC relay switch Diagram 1 DoubleSense system application 1 1 Sensor function DoubleSense detects sheets by sending invisible infrared light through the paper Without touching the paper the sensor can discover a double sheet on an early stage in the machine process The sensor collects opacity data i e light reduction data on a path stretching from lead edge to trail edge of the sheet before it indicates the paper status This method of scanning the entire sheet results in the most accurate and reliable detection that can be found on the market today The sensor is easily calibrated by pressing one single button no other manual operation is needed When the next paper sheet is run completely through the sensor the paper opacity profile is automatically scanned processed and stored in the sensor memory On the following papers in the feeding process data will be evaluated and compared to the calibrated value If the sensor happened to be calibrated on a double
51. tion The calibration errors are indicated by 1 LED3is GREEN for general ERROR Error type is shown at sub error level Press ERR key to access sub error level Go to APPENDIX 2 to read error type 2 Stop Error output O1 or Logic I O active 3 7 Passtime errors The sensor can warn the operator if the passing time is shorter or longer than the previous pass time during detection This can be used when checking for overlapping papers damaged papers or for confirming that the right paper enters the sensor If the paper pass time increases to more than 150 of the previous paper pass time If the paper pass time decreases to less than 67 of the previous paper pass time If the paper pass time during detection is less than 10 of the calibration pass time 10 times shorter If the paper pass time during detection is 10 times the calibration pass time 10 times longer Svensk Elektronikproduktion AB Page 15 43 If the paper has been present for more than five 5 seconds during detection The pass time errors are indicated by 1 LED3is GREEN for general ERROR Error type is shown at sub error level Press ERR key to access sub error level Go to APPENDIX 2 to read error type 2 Time Error output O2 or Logic I O active 3 8 Limitations The following factors influence the calibration and the detection of sheets 1 The printed colours reduce the infra red light that is sent through the paper A black
52. up to 120 g m Folded sheets up to 7 layers depending on colour opacity Pass time Edge delay 5 25 ms light strength setting 2 6 ms detection min 14 ms whole sheet at interval detection 20 ms Max 5 seconds Distance Distance between paper sheets in a flow minimum 13 milliseconds Power supply 12 24 Volt DC 5 Power 12 5 Max 600 mA Average 125 mA Min 80 mA consumption 424 4 59 Max 300mA Average70mA Min 40 mA Outputs PNP Active at U residual voltage 1 V 150 mA at U 12 V 250 mA at U 24 V NPN Active at 0 V residual voltage 1 V 250 mA max U Inputs PNP Active at U gt 0 8 NPN Active at U lt 0 2 Serial interface RS485 RS422 Sender amp Type AWG 24 Receiver cable Max temperature 80 C Max 300 Volt 1 0 and serial AWG 28 Modular cable Operation 70 C temperature I3 7 elf TT I II E EN50081 2 and EN50082 2 Svensk Elektronikproduktion AB Page 43 43

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