Leuze electronic OPSL 775 User manual

We reserve the right to make changes • DS_OPSL775_en.fm en 02-2011/06 50103772
Laser edge detector for counting in the
overlap flow
Counting rate > 1.5 million copies per hour
Edge detection of individual sheets from
0.1mm thickness
Detection range 5 … 150mm
Adjustable pulse stretching
Dynamic output pulse adaptation DPA
Simple mounting
5 … 150mm
12 - 30V
DC
Accessories:
(available separately)
Cables with M12 connector (K-D …)
Mounting systems
IEC 60947...
IEC 60947...
IP 54
Dimensioned drawing
ATransmitter
BReceiver
CPotentiometer
DControl buttons
EIndicator diodes
FM12 connector, 5-pin
Electrical connection
Plug connection, 5-pin
OPSL 775 Laser edge detector
Specifications and description
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Specifications
Optical data
Measurement range 1)
1) For objects with a luminosity coefficient of 18 … 90%
5 … 150mm
Edge height 0.1mm
Focus range 100 ± 10mm for 0.1mm edge height
Standard range 10 … 90mm/110 … 140mm for 0.3mm edge height
Threshold 5 … 10mm/140 … 150mm for 0.4mm edge height
Light source laser, pulsed
Wavelength 670nm (visible red light)
Output power 2)
2) Average value
<1mW
Pulse duration 3)
3) Typical value
8.3μs
Timing
Counting rate 4)
4) Dependent upon edge height, color and surface structure of the object to be detected.
The maximum value for 500 copies applies for an edge height of > 0.4mm only.
max. 500 copies
Object speed max. 4m/s for 0.1mm edge height,
max. 10m/s for 0.4mm edge height
Object sequence distances (overlap flow) > 2mm
Pulse width adjustment 1 … 1023ms, adjustable with 270° potentiometer
Dynamic pulse adaptation 12.5 … 50%
Delay before start-up 1.2s
Electrical data
Operating voltage UB12 … 30VDC (incl. residual ripple)
Residual ripple 15% of UB
Open-circuit current 100mA
Switching output …/4… pin 4: PNP, activated when edge detected
Signal voltage high/low (UB-2V)/2V
Output current max. 30mA
Sensitivity adjustable, 270° potentiometer
Indicators
Green LED POWER ready
Yellow LED EDGE edge detected internally
Yellow LED STATUS output pulse edge
LED yellow STATUS off/flashing calibration process in progress/standby mode
LED yellow DPA dynamic pulse adaptation activated
Mechanical data
Housing aluminum
Color black anodized
Optics cover glass
Fastening dovetail or
2 M6 screws in place of the profile strip
Weight 690g
Connection type 5-pin M12 connector
Environmental data
Ambient temp. (operation/storage) -5°C … +55°C / -30°C … +70°C
Protective circuit 5)
5) 1=transient protection, 2=polarity reversal protection, 3= short-circuit protection for transistor output
1, 2, 3
VDE safety class III
Protection class IP 54
Laser class 2 (in accordance with EN 60825-1)
Standards applied IEC 60947-5-2
Attention!
It is imperative that the safety notices in section 8 are observed
Order guide
Designation Part No.
Laser edge detector OPSL 775/4-150-S12 50115063
Tables
Diagrams
0,4
0,3
0,1
110
90
10
5
150
140
0,3
0,4
Minimum edge height [mm]
Measurement range [mm]
Remarks
Function
characteristics:
The OPSL 775 edge detector
is an optoelectronic sensor
for the contactless detection
of object edges.
Approved purpose:
This product may only be
used by qualified personnel
and must only be used for the
approved purpose. This
sensor is not a safety sensor
and is not to be used for the
protection of persons.
OPSL 775
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1 General
The OPSL 775 edge detector is especially suited for the counting of products being transported in layers on conveyor belts or
transport systems (overlap flow).
It is possible with the OPSL 775 to detect edges being conveyed within a range of 5 to 150 mm, as measured from the underside
of the device. The sensitivity range is dependent on the working distance. By focussing the laser beam to a distance of 100mm,
detection of the smallest possible edge height of 0.1mm is only possible within the focus range of 100mm ± 10mm.
If an edge is detected using the respective settings, the device generates a pulse at the switching output (pin 4). The settings
remain stored in such a way that they are protected against power interruption.
It is possible during the detection of edges that one and the same object is detected several times over. Commonly known as
multiple pulses, these can occur with a single object when, for example, print copies are being conveyed with the open edge and
not the "spine edge" leading. Likewise, interference caused by multiple pulses is to be anticipated for edges with discrepancies
in lettering or color or differences in reflection, but also for the individual pages of a bound printed copy. By selecting an
appropriate setting, these multiple pulses are selectively suppressed and the object can be correctly detected (see section 4).
2 Function buttons and indicators
Four LEDs serve as operational indicators and specify the current status of the device. Two potentiometers accessible from the
outside, as well as two control buttons, have been provided for operation, for example for adjustment and calibration during
installation.
Fig. 1: OPSL 775 - Device overview
Attention!
It is imperative that the safety notices in section 8 are observed
Device connection (M12 connector) Fixing rails
Operation indicators (status LEDs) Sensor arrangement (overlap position and direction of movement) Operating elements for sensor adjustment
OPSL 775 Laser edge detector
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2.1 Operation indicators
The operation indicators serve as a function check during operation, as well as for the calibration and adjustment process
The following information is displayed:
Table 1
2.2 Operational controls
Fig. 2: OPSL 775 - operational controls
Potentiometer for output pulse width( )
This potentiometer allows the output pulse width to be modified in stages, whereby turning to the left / right effects an increase /
decrease of the output pulse width (left limit stop: Maximum pulse width = 1023ms or right limit stop: Minimum pulse width = 1ms).
If the dynamic pulse adaptation (DPA) function is activated, the function of the potentiometer changes. See sections 4.3 and 4.5
for details regarding setting of the potentiometer.
Sensitivity potentiometer (Sens)
This potentiometer allows adjustment of detection sensitivity. To increase / reduce sensitivity, turn the potentiometer to the left
or right accordingly. See section 4.3 for details.
Control button for calibrating the working distance (CAL)
Once mounted, the device must be calibrated to the specified maximum working distance. Push this button once to initiate the
automatic calibration process. See section 4.1 for details.
Control button for dynamic pulse adaptation (DPA)
Pressing this button will activate / deactivate the dynamic pulse adaptation DPA (see section 4.4).
The DPA active LED indicates that the DPA program is active when it remains illuminated.
Designation Color of LED Illuminated Dark Flashing
POWER Green Device in operation Device not in operation –
EDGE Yellow
Shows that an edge has been
detected by the device.
Caution! Does not correspond
with the output pulse!
No edge detected –
STATUS 1)
1) This indicator has three functions:
1. During installation, the device is calibrated to a specified working distance. The indicator is extinguished during the calibration process.
2. The indicator is active (illuminated) while an output pulse is being generated.
3. If no output pulse is generated within 1s, the device switches to standby mode.
This is signaled by a flashing LED.
Yellow Output signal (pulse) Calibration process in progress Ready (standby)
DPA Yellow Dynamic pulse adaptation
active Fixed pulse active –
Control button
Dynamic pulse adaptation (DPA)
Control button
Calibration of working distance (CAL)
Potentiometer
Output pulse width /
faulty pulse suppression ( )
Potentiometer
Sensitivity (Sens)
OPSL 775
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3 Installation / alignment
3.1 General
In order that optimum functioning of the device can be guaranteed, the following points must be observed during installation:
1.The OPSL 775 must be installed in such a manner that vibrations are completely eliminated, otherwise there is a risk of counting
errors occurring.
2.Observe the permissible ambient temperature!
3.Avoid direct sunlight on the cover glass.
4.As a safeguard against hazards to persons, the laser beam should not be pointed at reflective surfaces in the case of an
uninterrupted overlap flow, as this may deflect the laser beam in an undefined direction (see section 8).
3.2 Mounting
Working distance and direction of overlap flow
Fig. 3: OPSL 775 - Working ranges
Threshold Standard range
Focus range
Focus distance
Direction of movement of overlap flow
Laser beam
OPSL 775 Laser edge detector
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3.3 Direction of overlap flow and direction of overlap
The device will only be capable of counting the overlap flow correctly if it passes the laser beam going in the opposite direction
(see fig. 4 left).
The OPSL 775 only counts those edges which are pointing in the conveying direction. Thus, in the case of an uninterrupted
overlap flow, the last copy is counted only once as the "falling edge" is not detected.
Fig. 4: OPSL 775 - Overlap flow and direction of overlap
3.4 Alignment
It should be ensured during installation of the device that the overlap flow passes parallel to the basic unit, or to its underside
(see fig. 5 left).
Fig. 5: OPSL 775 - Correct alignment
Notice!
The correct direction of overlap is stamped onto the front side of the device.
OPSL 775 OPSL 775
Direction of movement of the overlap flow
Rear edges are not counted!
Overlap position CORRECT Overlap position INCORRECT
OPSL 775
OPSL 775
CORRECT INCORRECT
OPSL 775
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4 Commissioning
As it is relatively difficult to check the apparent optimum settings for influence or effectiveness with regard to the respective
intended use, it is recommended that all setting procedures are performed with a defined reference sample. Furthermore, we
recommend the utilization of an oscilloscope to facilitate convenient visualization of the progress of the "Edge detected" output
signal (pin 4) in relation to the reference sample.
4.1 Calibrating the working distance
Following installation/mounting, the device must be calibrated to the specified working distance. The actual calibration is
performed automatically. A sheet of white paper is used as a reference surface.
The following steps are to be performed for calibration:
1.Set the Sens potentiometer for sensitivity to the middle position.
2.Place a sheet of white paper flat underneath the device so that the laser beam is directed onto it.
3.Press the CAL calibration button briefly once (> 50ms).
The status display is extinguished momentarily for the duration of the calibration procedure.
Calibration is concluded and it should now be possible to count the edges in the overlap flow with a constant working distance.
Under certain circumstances, the calibration procedure may have to be repeated. In the event that no edges can be detected,
please refer to the procedure for setting the OPSL 775 in section 5.
4.2 General
There are three possibilities for optimum adaptation of the device for the specified counting tasks:
1.Setting the sensitivity allows detection or suppression of small or less distinct edges.
2.A program is available which can be selected to perform a dynamic adaptation of the output pulse width automatically in
correlation with the sequential speed of the edges (recommended operating mode).
3.The device also offers the possibility of setting the desired output pulse width manually. This function is particularly suited
for more difficult application conditions as a blockage time for the suppression of faulty pulses can be set simultaneously with
a fixed output pulse width independent of the sequential speed of the edges.
4.3 Adjusting sensitivity (Sens potentiometer)
If the edges can not be detected correctly using the presetting specified in section 4.1, it is possible to increase the detection
rate by adapting the sensitivity. Adjustment is performed using the Sens (sensitivity) potentiometer. Rotation to the left or right
effects an increase/reduction of the sensitivity.
Medium sensitivity is wholly adequate for newspapers, magazines or similar objects. For extremely small edges or high sequential
speeds of edges, detection accuracy can be improved by increasing the sensitivity. Structured edges can lead to counting errors.
These counting errors can be avoided by reducing the sensitivity.
Fig. 6: OPSL 775 - Setting sensitivity
Potentiometer position:
High: High sensitivity
Medium: Medium sensitivity
Low: Low sensitivity
OPSL 775 Laser edge detector
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4.4 Dynamic pulse adaptation (DPA program)
The dynamic pulse adaptation has already been activated at the factory and is signaled via the DPA LED. Actuate the DPA button
for > 50ms in standby mode to deactivate the program; the DPA LED extinguishes. Pressing the button again will return you to
your original position.
Dynamic pulse adaptation is only suitable for relatively regular edge distances (example: printing of newspapers). The program
adapts the output pulse width permanently to the period directly following the object. The distance of the individual objects thus
corresponds to 100%. An output pulse corresponding to 50%, 25% or 12.5% of the period following the object is generated in
correlation with the setting of the pulse width ( ) potentiometer (see fig. 7).
If edges are recorded at extremely short distance and with high speed, it is possible that two edges are detected as a single pulse
and thus only counted as a single edge. In this case, counting reliability can be enhanced by reducing the output pulse width.
For blunt or rounded edges, counting accuracy is increased by extending the output pulse width.
Fig. 7: OPSL 775 - Effect of dynamic pulse adaptation
Table 2
4.5 Setting the output pulse width ( ) - Fixed pulse active (without DPA)
As already described in section 4.4, it is possible that counting can become impaired when edges are detected with very short
distances from each other and with high speed. In this case, counting reliability can be improved by reducing the output pulse
width. With blunt or rounded edges, counting accuracy is enhanced by extending the output pulse width. Output pulse width T
can be set using the pulse width ( ) potentiometer. Rotating to the left or to the right effects an increase or reduction of the
output signal pulse width.
Fig. 8: OPSL 775 - Output pulse with fixed pulse time
Attention!
The output pulse width can only be set to one of three stages: Maximum – Intermediate position – Minimum.
Notice!
Since the minimum output width pulse is 1ms, the output pulse width can not be reduced any further for the detection
of edges with high speed, meaning the output pulse width is a constant 1ms, regardless of the position of the
potentiometer.
Position Designation Output pulse width T [%]
Maximum max 50
Intermediate position -- 25
Minimum min 12.5
Attention!
It must be ensured that the output pulse width is not greater than the period following the edge!
We recommend using the dynamic pulse adaptation DPA wherever possible.
OPSL 775
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Switching between range modes
If the entire adjustment range of 1 … 1023ms is not required, a maximum adjustment range can be defined by one of three
different modes using an additional function (see table 3).
Table 3
The following procedure (fig. 9) must be initiated to set another range mode.
A customized resolution over 4 adjustment ranges is thus yielded.
Fig. 9: OPSL 775 - Procedure for switching over the range mode
Range mode Adjustment range [ms] STATUS 1) LED
1) The LED indicator is only valid for the changeover procedure when changing the range mode!
DPA active 1) LED
0 2)
2) Factory setting
1 … 1023
11 … 255
21…63
31…15
Attention!
If no button is actuated within 8s of calling up the function, the respective function is canceled and no change
is initiated. The system is automatically restarted.
Start
Switch off voltage supply
Press the CAL button and hold
pressed
Switch on voltage supply again
Release the CAL button
Alternative flashing of
DPA active and STATUS LEDs
The mode last stored is displayed
(table 3)
Continue to actuate the CAL
button until the desired mode is
indicated
(0 -> 1 -> 2 -> 3 -> 0 -> …)
The selected mode is displayed
(table 3)
Press the CAL button and hold
pressed
The new value is stored and
a reset is initiated,
release the CAL button
Alternative
flashing of LEDs?
End
NO
YES
OPSL 775 Laser edge detector
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5 Recommended procedure for setting the OPSL 775
Fig. 10: OPSL 775 - Setting procedure
Start
Sens potentiometer
in intermediate position
Perform calibration
Edge detection
possible?
NO
YES
Counting result
correct?
NO
YES
End
Counting result
correct?
NO
YES
Edge detection
possible?
NO
YES
Adjust Sens potentiometer
to the left: +; right: –
Adjust pulse width
potentiometer to the left: +;
right: –
Repeat calibration with Sens
potentiometer displaced from
intermediate position
Deactivate DPA and set pulse
width manually
Run through setting
range completely?
NO
YES
Run through setting
range completely?
NO
YES
OPSL 775
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6 Diagnosis in the event of an error
Table 4
7 Cleaning and storage
A damp cloth can be used for cleaning of the device housing.
Store in a clean, temperature-regulated and dry place!
Error Possible cause Remedial measures
POWER LED does not light up green No input voltage Check voltage supply
No edge detection possible
(EDGE LED not illuminated)
Working distance too great Check working distance and adapt as necessary
(section 3.2)
No calibration performed Perform calibration procedure (section 4.1)
Sensitivity not ideal Perform setting procedure (sections 4.3 or 5)
Direction of overlap flow/direction of movement
incorrect Check settings (section 3.3)
Object to be counted not suitable Test with reference (section 3)
No laser beam (Caution! Refer to the safety notices
in section 8!)Notify the manufacturer
Edge counting faulty
Sensitivity/calibration not ideal, influence of ambient
light
Readjust sensitivity (sections 4.3 or 5) /
repeat calibration procedure (section 4.1)
Error due to multiple pulses Check pulse width adjustment and readjust /
run DPA program (recommended) as necessary
Objects to be counted not ideal Test with reference
Sequential speed of edges outside of specification Check period following object, perform a test at low
speed
The output pulse width can only be
adjusted in minimum range Incorrect range mode set Switch mode over to desired range (section 4.5)
No output pulse, although EDGE LED is
detecting an edge Contact problem Check connection cable
Notice!
Faulty results due to changes within the overlap flow with regard to color change, surface structure and edge shape
of the objects to be counted or the distance of the objects from the detector may necessitate renewed calibration and
resetting of the device to the new conditions, and do not necessarily relate directly to malfunctioning of the device.
Attention!
The optics cover (laser beam emission) on the underside of the device may only be cleaned with a non-scratch cloth
specially designed for cleaning lenses (micro-fiber cloth)!
OPSL 775 Laser edge detector
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8 Safety notices
Beware of laser radiation!
The OPSL 775 edge detector operates with a class 2 red light laser in accordance with EN 60825-1.
The retina may sustain damage if the laser beam is observed for lengthy periods!
Never look directly into the laser beam! Never point the laser beam of the OPSL 775 at other people!
Beware of reflections of the laser beam from reflective surfaces during mounting and alignment of the
OPSL 775!
If any operating and adjustment devices other than those prescribed in the technical documentation are used,
or if other procedures are performed, or if the optical laser edge detector is used for any purpose other than
that for which it is intended, there is a high risk of dangerous exposure to radiation!
The utilization of optical instruments or devices together with the device increases the risk of damage to the
eyes!
Observe the valid legal and local laser protection requirements as stipulated within the most recent edition of
EN 60825-1.
Notice!
Affix the laser beam emission symbol included within delivery of the device to a point on the mounting location where
it can be clearly seen!
In the event of any doubt whatsoever, contact the respective person responsible for laser safety.
OPSL 775
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