Baumer DENEX Gripper LED User manual

USER MANUAL
FOR DENEX VERSIONS: 2009
DENEX
®
Gripper LED
FLDM 180C1101/S42

User Manual DENEX Gripper LED 2/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
READ THIS FIRST
Before installing, operating, opening, or applying the DENEX Gripper LED, read and
understand the contents of this manual.
Always observe the following warnings and cautions when operating or working on the
equipment.
CAUTION
Use of controls or adjustments or performance procedures other
than those specified herein may result in hazardous radiation exposure.
Do not stare into LED aperture.
Always turn off the sensor before moving or adjusting it.
The DENEX Gripper LED must be applied, installed, adjusted, and maintained only by
qualified personnel who are familiar with the operation of the DENEX Gripper LED and its
associated components.

User Manual DENEX Gripper LED 3/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
CONTENTS
1 INTRODUCTION _____________________________________________________4
2 RECEIVING AND HANDLING _________________________________________4
3 BASIC FUNCTION ___________________________________________________4
4 INSTALLATION______________________________________________________5
4.1 General Precautions____________________________________________________ 5
4.2 Mechanical Installation _________________________________________________ 5
5 ELECTRICAL INSTALLATION ________________________________________7
5.1 Power Connection _____________________________________________________ 7
5.2 Output Signal__________________________________________________________ 7
5.2.1 Output Signal - Connections ______________________________________8
5.2.2 Speed Sensor Input______________________________________________9
6 SOFTWARE FUNCTIONS____________________________________________10
6.1 Mode Setting _________________________________________________________ 10
6.2 Blocking Function_____________________________________________________ 10
6.3 Gripper Pulse Mode ___________________________________________________ 11
6.4 DIP-Switch Settings ___________________________________________________ 13
7 LED INDICATORS __________________________________________________14
7.1 The POWER-LED______________________________________________________ 14
7.2 The ”LED OFF”- LED __________________________________________________ 14
7.3 The OUTPUT- LED ____________________________________________________ 14
7.4 The STATUS- LED_____________________________________________________ 14
8 TECHNICAL SPECIFICATIONS ______________________________________15
9 ACCESSORIES AVAILABLE FROM DENEX___________________________16
9.1 Conversion kits _______________________________________________________ 16
9.1.1 Exchanging Ferag-Finger with Baumer proximity switch _____________16
10 MAINTENANCE AND REPAIRS_____________________________________17
10.1 Maintenance at Regular Intervals _____________________________________ 17
11 RETURNING EQUIPMENT _________________________________________17
12 WARRANTY ______________________________________________________18
13 TROUBLESHOOTING _____________________________________________19
14 APPENDIX _______________________________________________________21
15 Supplements _____________________________________________________23

User Manual DENEX Gripper LED 4/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
1 INTRODUCTION
WARNING
When a DENEX Gripper LED is combined with user
selected components to form a system, the user is responsible for proper selection of parts
and subsequent operation. This unit shall be installed, adjusted and serviced only by
qualified personnel who are familiar with the operation of the
DENEX Gripper LED and other system components. Serious personal injury and
equipment damage may result if this procedure is not followed.
2 RECEIVING AND HANDLING
Upon delivery of the equipment, thoroughly inspect the shipping containers and contents
for indications of damage incurred in transit. If any concealed loss or damage is
discovered later, notify the freight or express agent.
3 BASIC FUNCTION
The DENEX Gripper LED is a non-contact sensor which counts all kinds of products
carried in a Gripper. It senses the leading edge and generates one output pulse for every
product. Product thickness from a single folded sheet and up can be sensed without
adjustments.
The Infra Red-Light Emitting Diode (IR-LED) that is used produces a light beam which is
projected onto the stream. The reflected light from the spot is collected by two light
sensitive detectors P and R and is analyzed by a microprocessor. The difference in
reflected light that occurs when the light spot is temporarily hidden behind the passing
product edge provides the basic data for the sensor to determine a count.
The patented principle in utilizing two detectors - one for detecting the obstructed light and
the other for reference, enables the following unique benefits:
•Wide operating range
•High accuracy
•Insensitive to color of paper or print
•Insensitive to product thickness
The use of a microprocessor further enhances the flexibility and reliability of the unit.
Through the use of the microprocessor, the DENEX Gripper LED can be adapted to
different operating modes by changing DIP-switch settings which can be reached from
outside, via the lid on top of the unit.

User Manual DENEX Gripper LED 5/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
4 INSTALLATION
In order to assure the best possible operating conditions, it is essential that the following
instructions are followed exactly.
4.1 General Precautions
The DENEX Gripper LED should be installed in an environment where:
1. The equipment ambient temperature does not exceed 40º C.
2. The equipment atmosphere is free from highly flammable or combustible vapors,
corrosive chemical flumes, oil vapor, steam, excessive moisture and particles.
Avoid mounting the unit in places with strong vibrations since they can produce miscounts,
especially when thin products are counted. Make sure that the mounting bracket is rigid to
withstand vibrations.
4.2 Mechanical Installation
The sensor should be installed parallel to the conveyor and at a distance of 40 mm from
the copy edge, see figure 4.2.1. It is most important that the sensor is mounted the right
way. It can only count in one direction. ”The connector side of the sensor should meet the
edge first”.
As a “Target”, mount a white surface at 120 to 150 mm below the sensor, and parallel to
the bottom of the sensor. Check that the LED 4 indicates Target Status OK, see chapter 6,
”SOFTWARE FUNCTIONS”. Failure to comply will make the counter less accurate.
Mount the DENEX Gripper LED as close as possible to the Grippers without risking being
in contact with the Grippers. A 5 mm safety distance is recommended.
There must be at least 5 mm of air between the edge that the sensor should detect, and
the previous product.
If the sensor is to be used together with a Gripper pulse, it must be possible to move the
sensor sideways for the length of one Gripper, see figure 4.2.2. See further chapter 6.3,
”Gripper Pulse Mode”.

User Manual DENEX Gripper LED 6/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
Figure 4.2.1 Installing the sensor on a Ferag TTR Gripper conveyor.
120-150 mm
Support bars
Min 30 mm
Rec 50-60 mm
DENEX
Laser CopySensor™
GRIPPER LED
DENEX
Target plate
Figure 4.2.2 Installing the sensor on a Ferag TTR Gripper conveyor.

User Manual DENEX Gripper LED 7/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
5 ELECTRICAL INSTALLATION
The copy sensor has a 7-pin male connector with the following pin-out:
Matching female connector is Amphenol Tuchel T3476 001, delivered with the sensor.
Pin 1 : +24Vin
Pin 2 : + Output (Collector)
Pin 3 : + Speed Sensor Input
Pin 4 : - Speed Sensor Input
Pin 5 : - Output (Emitter)
Pin 6 : 0V
Pin 7 : No function (connected to pin 6 internally)
5.1 Power Connection
Proper wiring techniques are essential for successful system installation. To reduce the
effects of electrical noise interference and static discharge, the procedures outlined in this
section must be strictly followed.
The sensor shall be connected to 19 - 30V DC regulated power.
It must be free from transients!
Never connect or disconnect any cables when the power is on!
The normal current consumption is around 200mA.
5.2 Output Signal
The output is a normally open, opto-isolated transistor. Every output pulse is signaled as a
closing of the output; see “DIP-Switch Settings” in chapter 6.4.
The specification for the output opto-coupler is as follows:
Max load current: 150mA
Max voltage: 35V DC

User Manual DENEX Gripper LED 8/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
5.2.1 Output Signal - Connections
The output can be used for both "current source" and "current sink" depending on what is
required for the connected equipment. It can be normally open or normally closed, see
chapter 6, ”SOFTWARE FUNCTIONS”.
In current source mode, the sensor output will give a positive output pulse when active.
In current sink mode, the sensor output will give a negative pulse.
Figures 5.2.1.1 and 5.2.1.2 show a common 24 VDC as power supply and as the supply
for the pulse. It is possible to have different power supplies. In that case, the 24V-power is
connected to pins 1 and 6, and the output is connected to pins 2 and 5, see figure 5.2.1.3.
Figure 5.2.1.1 Electrical connection, common 24VDC-supply. Current source (PNP).
Figure 5.2.1.2 Electrical connection, common 24VDC-supply. Current sink (NPN).
+24V Examples of input stage
TTL
0V
DENEX CopySensor™ Control system/Stacker/Totalizer
or
Figure 5.2.1.3 Electrical connection, separate supply for power and pulse.
Copy
Sensor

User Manual DENEX Gripper LED 9/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
5.2.2 Speed Sensor Input
There is a possibility to connect an input signal from a speed sensor, such as an encoder
giving for example 100 pulses per Gripper, or a proximity switch that senses the Grippers,
in order to give information conveyor speed and Gripper position to the DENEX Gripper
LED. This information can help the sensor to increase accuracy, especially for productions
with two papers per Gripper.
The speed sensor input of the DENEX Gripper LED is opto-isolated, i.e. there is a
separation between the DENEX Gripper LED’s and the Speed Sensor’s grounds.
The input should be min. 4.5V and max. 28V.
The maximum allowed frequency is 2.5 kHz.
Connector
Input signal 3
4
Figure 5.2.2.1 Input stage for speed sensor input.
There is a variety of types of proximity switches available: NPN, PNP, normally open, and
normally closed. However, the principle is the same; when a Gripper is close to the switch,
it will change status on the output.
The DENEX Gripper LED will sense this change and use it in the Blocking Function routine.
See chapter 6, ”SOFTWARE FUNCTIONS”.

User Manual DENEX Gripper LED 10/24 Baumer Electric AG
Version 2013-02, V1.4 www.baumer.com Frauenfeld, Switzerland
6 SOFTWARE FUNCTIONS
The real power with a microprocessor based sensor is that the sensor learns what the
products and the stream look like and make decisions according to this.
Before actual settings are discussed, first a short description of the major functions and
terms.
6.1 Mode Setting
The DENEX Gripper LED has a Single Production Mode and a Double Production Mode.
The difference is the Blocking Zone, see below. There are also modes for replacement of
mechanical fingers
There are four DIP-switches that tell the sensor which application it should be set for.
It is very important to set the right application!
6.2 Blocking Function
This function will eliminate false counts due to double edges or a cut-edge-first delivery.
The sensor will count edges coming within the blocking zone as one product. In
productions using stitches, extra pulses due to the stitch are blocked out by this function.
The blocking zone is a dynamic value that constantly adapts to the average distance
between copies. It will be either 15% or 30 % of the mean lap, depending on application.
The average distance between copies is 100%, see figure 6.2.1.
If speed sensor pulses are used, the blocking will switch to a fixed number of pulses
instead of a dynamic time.
100%
15%
30%
15%
30%
100%
15%
30%
15%
30%
100%
Figure 6.2.1 The principle of the dynamic blocking function. Blocking Zone is marked with
grey. 15% is the first half, and 30% is whole area.