Pepperl+Fuchs UDC-18GMA-400-3E2 User manual

FACTORY AUTOMATION
Instruction manual
Ultrasonic Double Sheet
Monitor
UDC-18GMA-400-3E2

With regard to the supplyof products, the currentissueof the following documentis applicable: The
General Terms of Delivery for Products and Services of the Electrical Industry,
published by the Central Association of the "Elektrotechnikund Elektroindustrie (ZVEI) e.V.
including the supplementary clause: „Erweiterter Eigentumsvorbehalt“.
We at Pepperl+Fuchs recognise a duty to make a contribution to the future,
For this reason, thisprinted matter is produced on paperbleached without the use of chlorine.

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Table of Contents
Da te of edi ti o n: 12/ 17 /04
3
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
1 Description of sensor functions ......................................... 5
2 Working principle................................................................. 5
3 Function input ...................................................................... 6
4 Measuring system................................................................ 6
5 Installation and adjustment................................................. 6
6 Commissioning and parameter assignment...................... 8
6.1 Switching on....................................................................................... 8
6.2 Normal mode...................................................................................... 8
6.3 Output pulse extension ..................................................................... 9
6.4 Display mode...................................................................................... 9
6.5 Parameter assignment....................................................................... 9
6.6 Modes................................................................................................ 11
7 Technical data .................................................................... 13
7.1 Electrical connection....................................................................... 14
7.2 Dimensions....................................................................................... 14
8 Accessories........................................................................ 15
Hints
These operating instructions provide information on how to use the product pro-
perly. They must be read andobserved by all persons who use or work with this
product. This product is only abletoperformthe functions for which it wasdesig-
nedif it isused and operated in accordance with informationprovided by
Pepperl+Fuchs.
The warrantee assumedby Pepperl+Fuchs for this product is null andvoid if it is
not used andoperatedinaccordance with its proper useas described by
Pepperl+Fuchs
Changestothe devices or components and theuse of defective or incomplete de-
vices or components are not permitted. IRepairs to devices or components may
only be performed by Pepperl+Fuchs or authorized work shops. These work
shops are responsible for acquiring the latest technical information about
Pepperl+Fuchs devicesand components. Repair tasks made on theproduct that
are not performed by Pepperl+Fuchs are not subject to influence on the part of

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Hints
Date of edition: 12/17/04
4Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Pepperl+Fuchs. Our liability is thus limitedto repair tasks that are performed by
Pepperl+Fuchs.
The preceding informationdoes not change information regarding warrantee and
liabilityin the terms and conditions of sale and delivery of Pepperl+Fuchs.
Subject to technical modifications.
Symbols used
This manual usessymbolsto presentimportant information onoperating andwor-
king safely with the ultrasonic double sheet control UDC-18GMA-400-3E2. The
meaning of these symbols is as follows:
Recommendation for the user
Observing thisinformationwill makeit easier toplacetheultrasonic
doublesheet control UDC-18GMA-400-3E2 in operationand work
withit.
This symbol warns the user of possible improper functionality. Failure
to heed this warning may result incomplete failure of the equipment
or other devices that are connected.
Note
Attention

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Description of sensor functions
Aus g ab ed atu m 12/ 17 / 04
5
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
1 Description of sensor functions
The ultrasonicdouble sheet monitor isusedin all situations inwhichthe au-
tomatic distinction between single and double sheets is required in order to
protect machines or avoid waste production. The double sheet monitor is
based on the ultrasonic through-beam principle. The following can be detec-
ted:
• Nosheet,i. e. air
• Individual sheet
• Double sheet or multiple sheets (no distinction can be made for the num-
ber of sheets)
A microprocessor system evaluates the signals. The appropriate switch out-
puts are set as a result of the evaluation. Changes in ambient conditions such
as temperature and humidity are compensated for automatically.
2 Working principle
The measuring principle of the double sheet control is based on measuring
andevaluating the transmittedsound amplitude through asheet of paper. If
there is no paper, no sound is absorbed and the received signal reaches its
maximum level. If there are two sheets of paper, one on top of the other, al-
mostallofthesignalisabsorbedduetomultiplereflectionbetweenthelayers.
The amplitude of the signal passing through thus reaches a minimum level.
The thicker or denser a given type of paper is, the lower the portion of sound
that will pass through it according to the working principle. Because of this,
the functionalityof thedoublesheet control is limitedto typesof paper that fall
within a specific range. Paper that is too thin allows too much sound to pass
through sothatit is notsufficiently different fromair. Ontheother hand, paper
that is too thick absorbs so much of the sound that the amplitude for single
sheets is already in the range of a double sheet.
Therefore, the double sheet control offers the user 4 different programs for
different ranges of material, making itpossible toadjust to the ideal settingfor
different applications. There isno need to perform TEACH-IN for single sheet.
This makes the product more user-friendly. Fluttering movements of the pa-
per do not affect reliable operation of the DSM.

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Function input
Date of edition: 12/17/04
6Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
3 Function input
Function input (wire colour pink, PK) is used to adjust the sensor and assign
parameterstoit. Thefollowingfunctions are available:
• Alignment aid
• Program selection
• Output pulse extension
During normal operation, the function input must always be securely connec-
ted with +U
B
or -U
B
, to avoid possible interference or improper functionality.
4 Measuring system
A complete unit consists of an ultrasonic emitter unit and an evaluation and
receiver unit. The sensor heads are optimally adjusted to each other when
theyleavethe factory. Therefore, theyshould not beusedseparately or ex-
changed with other devices of the same type.Theplugconnector ontheemit-
ter/receiver connectioncableis onlyintended tobeusedforeasier mounting,
notto replaceunits.
5 Installation and adjustment
Correct functionality of the sensor can only be ensured if the emitter and re-
ceiver are adjusted so they are exactly centred on each other. Inaddition, the
UDC-18GM offers an electronic alignment aid (see chapter 6.6.1 "Alignment
aid" onpage11).
Recommended spacing between the sensor heads:d=40mm... 45mm
Angular misalignment:
α < +/- 1°
Maximummisalignment: s< +/- 1 mm
(see Fig. 5.1 and Fig. 5.2 on page 7)

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Installation and adjustment
Aus g ab ed atu m 12/ 17 / 04
7
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
Fig. 5.1: Recommended spacings and angular settings
Fig. 5.2: Max. permissible misalignment of the sensor heads
To ensure proper functionality of the double sheet control, the sensor heads
must be aligned at an angle of from
β = 0° to +/- 45° to the perpendicular in
reference tothe sheet plane; seeFig. 5.1.
Installing the sensor heads vertical to the sheet plane is adequate for most
applications .
With very thin sheets, we recommend aligning the sensor heads vertically to
the sheet plane (
β = 0°); see Fig. 5.1.
For very thick sheets, we recommend installing the sensor heads at an angle
of
β =35°; see Fig. 5.1.
The sheet is guided at a distance of a= 10 mm ... 15 mm above the emitter;
see Fig. 5.1.
Recommended distances
d
b
a
a = 5 ... 15 mm
b ≥10 mm
d = 40 ... 45 mm
β= 35˚
(for very thick Papers)
a
d
b
β
Dimension b: see tablein chapter programs
α
s
α< +/- 1˚
s < +/- 1 mm
Thin foil detection

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Commissioning and parameter assignment
Date of edition: 12/17/04
8Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
To prevent accumulations of dust, the emitter should be installed below so
that the emitter is always transmitting upward. The ultrasonic signal has a
self-cleaning effect. The sensor heads can be fastened in place with the enc-
losed nuts.
The sound lobe must be completely covered by the paper. That means that
the sensor heads must beat least b= 10 mm away fromthe side edge of the
paper (see illustration). The direction inwhichthe paper is running makes no
difference.
If several DSMs (ultrasonic double sheet monitors) willbeoperated in the im-
mediate vicinity of each other,acoustic separation shouldbe provided tokeep
them from interfering with each other. This can be achieved, for example, by
positioning metal sheets between them. Installing the units more than
500 mm apart typically results in satisfactory acoustic separation without any
additional measures. If one DSM systemis emitting signals directly at the re-
ceiver of a second system, there may be interference at a distance of up to
1.5m.
6 Commissioning and parameter assignment
6.1 Switching on
The sensor is equipped with 6 connections. The functionality of the connec-
tions isdescribedin the following table. The function input (PK) isused toas-
sign parameters to the sensor. (See Output pulse extension, Alignment aid
and Program selection). During normal operation, the function input must al-
ways be securely connected with +U
B
or -U
B
, toavoid possible interference
or improper functionality.
6.2 Normal mode
The sensor is working in normal mode if the function input (PK) is applied to
-U
B
or +U
B
when the power source (Power-On) is supplied, as shown in the
output pulse extension table (see chapter 6.3 "Output pulse extension" on
page 9).
Colour Switching on Comments
BN +U
B
WH Switch output for singlesheets Pulse widthcorresponds to the event
BK Switch output for doublesheets Pulsewidthcorresponds totheevent
GY Switch output for air Pulsewidthcorresponds totheevent
PK -U
B
/+U
B
Function input for parameter assignment/pulse
extension
BU -U
B

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Commissioning and parameter assignment
Aus g ab ed atu m 12/ 17 / 04
9
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
Displays:
LED yellow: Detection of air
LED green: Detection of single sheets
LED red: Detection of double sheets
Switch outputs:
The switch outputs are only active in normal operation!
White: WH Single sheet output
Black: BK Double sheet output
Gray: GY Air output
6.3 Output pulse extension
Switching the function input (PK) on to-U
B
or +U
B
makes it possible to select
aminimum pulse width of 120 ms for all output pulses of the three switch out-
puts.
Please note:
This can result in a conditionin which morethan oneswitch output is switched
through!
6.4 Display mode
The selectedparameter assignment of thesensor canbe displayed byswit-
ching the function input (PK) to voltage-free during normal operation. The
green LED displays the program number (the number of flashing pulses (1 ...
4) = the program number).
The outputs areinactive atthistime.
If the function input (PK) is unconnected when power is supplied(Power-On),
the sensor will also workin displaymode (green LED flashes).
If thefunction input (PK) breakesdue toanerror whilethe device isin normal
operation mode (broken cable, coming loose because of vibration), display
mode acts as a fault display (green LED flashes).
6.5 Parameter assignment
The sensor is equipped with 4 programs for different ranges of application.
This makes it possible to work with awide range of material. The user can se-
lectthe programbest suitedfor a specific application.
The default setting, Program 1, is designed so that no change in the set-
ting is required for most applications.
Switching on(PK) Operating behaviour (after Power-On)
-U
B
No output pulse extensionforswitchoutputs
+U
B
Output pulseextensionof all switch outputs toat least 120 ms

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Commissioning and parameter assignment
Date of edition: 12/17/04
10 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
6.5.1 Programs
*) The measurements were made under the following conditions: d= 45 mm,a=10 mm, β = 0°
**) The measurements were made under the following conditions: d= 45 mm,a= 10 mm, β = 35°
6.5.2 Procedure for assigning parameters
It is possible to switch to additional parameter assignment modes from the
display mode:
Alignment aid mode -->
Programselection mode-->
Alignment aid mode -->
When the functioninput (PK) is applied to-U
B
(for>500ms), themodechan-
ges. When the "Program selection“ mode is active, switching onfunction input
(PK) onto +U
B
(for > 500 ms) selects the next program level.
Disconnecting the power supply causes the system to exit the current mode
with the selected program change.
The switch outputs are not active while parameters are being assigned to the
sensor!
Program
number Notes
*
Rangeof materials Dimensionb
(fig. 5.1)
1 Default setting,standard paper 20 - 1200 g/m
2
> 15 mm
2 Thick paper, cardboard,fine corrugatedboards
(DIN 55 468
- 1)andthin sheet metal** > 100 g/m
2
> 20 mm
3 Thinpaper 20 –250 g/m
2
> 11 mm
4 Extremely finepaper < 40g/m
2
>8 mm

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Commissioning and parameter assignment
Aus g ab ed atu m 12/ 17 / 04
11
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
Fig. 6.1: Parameter assignment
6.6 Modes
6.6.1 Alignment aid
During installation, the DSMcan provide an adjustmentaidfor optimal align-
ment of the emitter to thereceiver.
If the sensor detects an areaof air (yellow LEDis lit) the DSM will begin to
display the intensity of the measured amplitude signal after 3 seconds:
If thesignal is weak, the yellow LEDwillflashat a slowrate
As the intensity of thesignal increases, the rate at which the LED flashes be-
comes faster
At optimal alignment (maximum signal intensity), the yellow LED is conti-
nuously lit.
The single sheet function (green LED) and double sheet function (red LED)
continues to beactive. This makes itpossibletocheck for correct functionality
of the double sheet control.
6.6.2 Program selection
In the programselection mode, the current programis displayed by the green
LED (number of flashing pulses = programnumber). Applying the adjustment
input (PK) to +U
B
(for > 500 ms) causes the next program to be selected in
cyclic sequence (program 1 follows through to program 4).
Power ON Normal mode
Indication mode
activate/deactivate
output pulse
prolongation
... and function input
(PK) unconnected Function input
(PK) unconnected
... and function input (PK)
connected to +UB or -UB
no function toggle cyclically
next program
Indication mode
Alignment aid
(yellow LED) Program select (green LED)
+UB
-UB
-UB
-UB
+UB+UB

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Commissioning and parameter assignment
Date of edition: 12/17/04
12 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
Notes:
Installation, commissioningandmaintenance mustonly beperformed by qua-
lifiedspecialists. The sensor headsmust beinstalledwith great care. If thede-
vice is not used for a purpose for which it was intended, reliable functionality
of the doublesheet control cannot be guaranteed. Making changes to or tam-
peringwith the deviceisnot permitted.
This sensor is not suitable for detecting contact points or labels.
Pepperl+Fuchs does offer equipment developed especially for
thispurpose.
Extremely light papers (for example handkerchiefs) or perforated
papers (for example sheetsof stamps) arenot alwayssuitable for
double sheet detection because of their physical characteristics.
Material that represent double sheetsin and of themselves cannot
be used, for example multiply coated material with air cavities in
them. These may result from damage (kinking) of paper, for
example.
Due to the great variety of types of paper, cards and foils, we
strongly recommend trying out the desired range of detection
material as part of an approval procedure, for example, before
using the sensor.This will ensureoptimal reliabilityin detection.
The sheets must not touch the sensor heads during operation.
Note
Note
Note
Attention

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Technical data
Aus g ab ed atu m 12/ 17 / 04
13
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
7 Technical data
Table 7.1: Technical data
General data
Detection range 20 ...60mm, optimal distance:45 mm
Transducer frequency 395 kHz
Displays/operating elements
LED green Display: single sheet detected
LED yellow LEDdisplay:Nosheet detected(air)
LED red LEDdisplay:Doublesheetdetected
Electrical data
Operating voltage 20 ...30V DC, ripple10 %SS
No-load supply currentI
0
< 80 mA
Input
Input type Function input
0-level: -U
B
...-U
B
+ 1 V
1-level: +U
B
- 1 V ... +U
B
Pulselength
≥ 100ms
Impedance
≥ 230k Ω
Output
Outputtype 3switchoutputs pnp, normally open contact
Ratedoperatingcurrent I
e
3x 100mA, short circuit/overload protected
Voltage drop U
d
≥ 2 V
Switch-on delayt
on
Approx.25 ms
Switch-off delayt
off
Approx.25 ms
Conformity to standards
Standards EN60947-5-2
C-ULlisted: 57M3, INDCONT. EQ., powered by Class II power
source
Ambient conditions
Ambienttemperature 0... 60 °C(273... 333K)
Storagetemperature -40... 70 °C(233... 343K)
Mechanical data
Protection class IP67
Connection 2m,PVCcable0.14 mm²
Materials
Housing Brass, nickel-plated, PBT plastic components
Transducer Epoxy resin/hollowglass bead mixture;polyurethane foam
Weight 150 g

Ultrasonic Double Sheet Monitor UDC-18GMA-400-3E2
Technical data
Date of edition: 12/17/04
14 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group •Tel.:Germany (06 21) 7 76-0 • USA (330) 4 25 35 55 • Singapore 7 79 90 91 • Internet http://www.pepperl-fuchs.com
7.1 Electrical connection
Fig. 7.1: Electrical connection
7.2 Dimensions
Fig. 7.2: Dimensions
(BN)
(PK)
(WH)
(BK)
(GY)
+UB
-UB
(BU)
UOutput double sheet
Output air
Output single sheet
Function input
Evaluation unit with
receiver unit
Emitter unit
wires 25 mm with
wire end ferrules
18
91
10
45
M18x1
4
24
LEDs
40
24
10
M18x1
l = 210
l
= 160

With regard to the supplyof products, the currentissueof the following document is applicable: The
General Terms of Delivery for Products and Services of the Electrical Industry,
published by the Central Association of the "Elektrotechnikund Elektroindustrie (ZVEI) e.V.
including the supplementary clause: „Erweiterter Eigentumsvorbehalt“.
We at Pepperl+Fuchs recognise a duty to make a contribution to the future,
For this reason, thisprinted matter is produced on paper bleached without the use of chlorine.

Worldwide Headquarters
Pepperl+Fuchs GmbH · Königsberger Allee 87
68307 Mannheim · Germany
Tel. [phone] · Fax [phone]
e-mail: [email protected]om
USA Headquarters
Pepperl+Fuchs Inc. · 1600 Enterprise Parkway
Twinsburg, Ohio 44087 · Cleveland-USA
Tel. [phone] · Fax [phone]
e-mail: [email protected]hs.com
Asia Pacific Headquarters
Pepperl+Fuchs Pte Ltd. · P+F Building
18 Ayer Rajah Crescent · Singapore 139942
Tel. [phone] · Fax [phone]
e-mail: [email protected]hs.com
www.pepperl-fuchs.com
SIGNALS FOR THE WORLD OF AUTOMATION
Subject to reasonable modifications due to technical advances · Copyright Pepperl+Fuchs · Printed in Germany · Part. No.
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