Prime Controls DS1510 User manual

OPERATING INSTRUCTIONS
MODEL DS1510 DOUBLE SHEET DETECTOR
DESCRIPTION
The Model DS1510 Double Metal Sheet Detector comprises a control module in a sheet metal
housing with two probes to form a system that detects the thickness of metals passing between
the probes. The thickness is reported via two form C relays as “nominal”, “over”, “under” or
“nothing”. This system may be used on automatic sheet feeders where double or overlapped
sheet material may jam or damage the receiving machine or ahead of roll forming equipment to
insure lap welds do not damage the equipment. A double feed or overlap produces an output to
stop the machine or signal the operator.
October 3, 2019
CONTROL I/O PROBES
SIGNAL/MESSAGE
MESSAGES
Pr 01 flashing -
Transmitter Probe Fault
Receiver Probe Fault
Pr 02 flashing -
Pr 03 flashing -
Both Probes Faulting
CA - Calibration Mode
CA nn flashing -
Calibration Fault
Er nn flashing -
Fatal System Fault
DS1510
DOUBLE SHEET DETECTOR
NOMINAL
UNDER
OVER
GAP
AC AC
POWER OVER UNDER
RELAY RELAY
CAL
COM RCVR
RCVR
SHLD
SHLD TMTR TMTR
RESET COM
AUXIN COM
AUXO
COM
FAULT
COM
100 - 240 AC OUTPUTS
INPUTS
CALIBRATE
PRIME
CONTROLS, INC.


DESCRIPTION
2
System Features
The DS1510 is a highly flexible gauging system with a variety of features, some of which may be
enabled or disabled through the positioning of DIP switches located beneath the control module
cover. The various features include:
•Accommodates a family of probes allowing double detection on metals, from foil to heavy
plate.
•Manual calibration on single and double thickness for all metals.
•Manual calibration on single thickness for steel.
•Automatic calibration on steel after material absence for a preset trigger time.
•Automatic nominal adjustment for roll stock of varying thickness.
Each of these features is described in greater detail later in this document.
Control Module
The features of the control module include:
•Universal power input accommodates AC voltages from 100 to 240 volts.
•Removable terminal blocks for quick change-out of the control module.
•Separate form C relay outputs for independent reporting of OVER and UNDER conditions.
•LED indicators report the current gage states of NOTHING, UNDER, NOMINAL, and
OVER.
•Automatic setup of system gain and operating parameters.
•External or front panel calibration through a contact closure or the front panel push-button
switch.
•Two calibration memories that are selected through the AUXIN terminal. The memory
contents are retained when power is removed from the unit.
•Latching OVER and UNDER outputs that are cleared by asserting the RESET input.
•A fast, open collector logic output that is ON for nominal readings and OFF for OVER or
UNDER.
•An open collector FAULT output that may be connected to a master controller for monitoring
fault and gauge-not-active conditions.
•Probe fault reporting on the two digit display warns of broken or disconnected probes or
cables.

DESCRIPTION
3
Control Module Indicators
The function of the indicators and display on the DS1510 control module are described in the
following paragraphs:
1. OVER LED is ON whenever the material thickness exceeds the calibrated nominal value by
more than the set tolerance.
2. NOMINAL LED is ON whenever the received signal is within the specified tolerances,
both over and under.
3. UNDER LED is ON whenever there is material between the probes but the material thinner
than the calibrated nominal value by more than the set tolerance.
4. NOTHING LED is ON whenever the received signal goes beyond the measuring range of
the instrument indicating an absence of material between the probes.
5. The OVER, NOMINAL, UNDER, and NOTHING LEDs flash in succession when the
system is in calibrate mode.
6. Numeric Display indicates the level of the signal from the receiving probe and reports error
or status conditions. During gauge operation the value on the display reflects the strength of
the signal from the receiving probe. Thicker materials reduce the level of the signal
reaching the receiving probe, consequently the displayed value is lower for thicker material
and higher for thinner material.
Control Module Calibrate Push Button
The push-button switch on the front panel of the control module serves to initiate the
calibration process and to make adjustments to two numeric parameters, the automatic
calibration trigger time (Ct), and the calibration delay time (Cd). The trigger time is adjustable
from 0.1 minutes (6 seconds) to 25 minutes. The calibration delay is adjustable from 0 seconds
to 9.9 seconds. The calibration delay is not available in units with firmware version numbers
smaller than 3.9.
To initiate calibration, simply press the push button and release it within 3 seconds.
To view the current value of a parameter, press the push button and hold it for more than 3
seconds until the appropriate parameter identifier appears on the digital display. After the
parameter identifier appears, release the push button and the current value of the parameter
displays for 5 seconds. To retain the current value of the parameter, simply allow the 5 second
display interval to elapse. The display reverts back to displaying signal strength.
To change the value of a parameter, press the push button and hold it for more than 3 seconds
until the appropriate parameter identifier appears on the digital display. After the parameter
identifier appears, release the push button and the current value of the parameter displays.
Press the push button while the parameter is displaying and the value increments, first slowly
then more rapidly. For more precise control of the value adjustment, simply tap the push button
repeatedly until the desired value is displayed. All parameters roll back to their minimum
values after reaching the maximum value. To retain the adjusted value of the parameter, simply
allow the 5 second display interval to elapse. The display reverts back to displaying signal
strength.

DESCRIPTION
4
Control Module Configuration Switches
An eight position DIP switch is located beneath the front cover on the main control circuit
board to the left of the displays These switches must be set to enable the features of the system
that are appropriate to your application. Any time a switch setting is changed, the control
module must be powered down and back up to install the change. The switches are read only at
power up.
The functions of the switches are as follows:
Switches 1 & 2 Set the relay response time
SW 1 SW 2 Effect
OFF OFF Minimum delay
ON OFF 100 millisecond delay
OFF ON 500 millisecond delay
ON ON 1 second delay
Switch 3: OFF Calibrate on single and double.
ON Calibrate on single only.
Switch 4: OFF Disable reference tracking.
ON Enable reference tracking.
Switch 5: OFF Probe and gap assessment occurs every time the system is powered up.
ON Probe and gap assessment is bypassed at power-up if the AUXIN input is
high. If AUXIN is held low (connected to COM), probe and gap
assessment occurs at power-up.
Switch 6: OFF Disable automatic calibration trigger.
ON Enable automatic calibration trigger.
Switch 7: OFF AUXO is ON for OVER and for UNDER, otherwise OFF
ON AUXO is ON for OVER, NOM, UNDER, OFF for NOTHING
This option not available for Versions 4.5 or lower.
Switch 8: OFF: The state of the relays for NOTHING in the gap is the same as for the
NOMINAL state.
ON: The state of the relays for NOTHING in the gap, is OVER for the OVER
relay and UNDER for the under relay.
Control Module Polarity Jumpers
Each of the logic inputs (CAL, RESET, and AUXIN) to the DS1510 has associated with it a
two position jumper plug located under the front cover and immediately behind its associated
connector. These jumpers allow the inputs to be driven by a sinking or sourcing device. When
the jumper plug is installed on the pins closest to the connector, the input is set up for a
sourcing driver. When installed on the two pins farthest from the connector, the input is set up
for a sinking driver, or dry contact between the input and COM.
Whether set for sinking or sourcing drivers, the input is active (ON) when the signal at the
terminal is low (at COM).

APPLICATION CONSIDERATIONS
5
APPLICATION CONSIDERATIONS
Choice of Probes
The DS1510 accommodates a number of Prime probes but is most often used with the P1000B,
P70A, and P70CS probes. The P70A and P1000B probes are potted and completely sealed
units with permanently attached cables. The P70CS probes are potted with connectors for easy
removal. The same probe type is used for transmitter and receiver and is not polarized.
The table below provides rule of thumb information for probe selection.
Probe Housing Connection Gap Application
P1000B Aluminum block Cable 0.5” to 1.25” 0.060 and thicker
P70A Threaded steel barrel Cable 0.5” to 0.75” 0.004 to 0.060 steel
P70CS Smooth stainless barrel Connector 0.5” to 3.00” 0.004 to 0.060 steel
Probes with non-ferrous (aluminum and stainless steel) housings offer greater probe separation.
Probes with steel housings are not affected by the material used for mounting. Probes with
aluminum or stainless steel housings are affected by steel near them including mounting clamps.
To realize maximum separation with the P70CS type units, the probes must be mounted in non-
ferrous clamps, e.g. Nylatron or 303 stainless steel.
Prime offers a number of other probes that allow the DS1510 to be applied to a wide range of
materials including magnesium, copper, stainless steel, and aluminum. For more information or
assistance in selecting the appropriate probes, contact Prime Controls.
Calibration Considerations
The DS1510 offers three different modes of calibration.
1. Manual calibration on single and double thickness material (two-hit calibration). In this
mode, a sample of the nominal thickness is placed between the probes and the CAL push
button or optional external cal switch is pressed. Then a second thickness (or multiples of the
original) are placed between the probes and the CAL push button or external cal switch is
again pressed. Calibration is complete.
2. Manual calibration on single thickness steel (single-hit calibration). In this mode, calibration
can be initiated through a press of the CAL push button or an optional external cal switch
prior to material entering the gap between the probes. The DS1510 enters a wait state until
such time as material is fed between the probes. If the calibration delay parameter (Cd) is set
to zero, calibration occurs within 100 milliseconds after material is sensed between the
probes. For slow moving material, this delay can be increased (up to 9.9 seconds) to insure
the material fully covers the probes before calibration occurs. See the Control Module
Calibrate Pushbutton section earlier in this document for the parameter adjustment
procedure.

APPLICATION CONSIDERATIONS
6
3. Automatic calibration on single thickness steel. In this mode, calibration process is the same
as for the manual single-hit calibration except that the calibration process can be initiated by
the expiration of a timer within the DS1510. The timer (Ct) can be set to a value from 0.1
minute (6 seconds) to 25 minutes. When the DS1510 detects the absence of material between
the probes, the timer count-down begins. If the count-down expires before material is sensed,
the DS1510 enters calibration mode, waiting for material to be fed. If the calibration delay
parameter (Cd) is set to zero, calibration occurs within 100 milliseconds after material is
sensed between the probes. For slow moving material, this delay can be increased (up to 9.9
seconds) to insure the material fully covers the probes before calibration occurs. See the
Control Module Calibrate Pushbutton section earlier in this document for the parameter
adjustment procedure.
NOTE
The adjustable calibration delay parameter (Cd) is only available in systems with firmware
version 3.9 or higher. Older systems can be upgraded at the factory for a nominal fee. See
Firmware Version section later in this document for determining the firmware version of your
system.
The choice of calibration mode is application dependent since each mode has its advantages and
disadvantages. Two-hit calibration offers the possibility of discriminating changes in metal
thickness that are far less than 2 to 1 since the system is calibrated on samples of the thickness
range to be discriminated.
Relay Response Time
For most applications it is desirable that the OVER relay respond as quickly as possible. For
thinner materials the response time is as fast as 3 milliseconds. For very thick metals the
response time can be as long as 40 milliseconds.
If very fast response times are undesirable, the action of the relays can be delayed through the
setting of DIP switches 1 and 2 as described under “Control Module Configuration Switches”
earlier in this document.
Tracking Nominal
The tracking nominal feature of the DS1510 (Switch 4 ON) is typically used on roll-fed material
that varies in thickness over its length. The unit keeps a slow average of the thickness and
gauges relative to the average rather than relative to a fixed nominal calibration value. The
average is referred to as the tracking nominal. The tracking nominal is allowed to shift by as
much as 50% in thickness in either direction from the calibrated nominal.
Whenever no material is sensed between the probes, the calibrated nominal is reinstated
regardless of the final thickness of the previous material.

APPLICATION CONSIDERATIONS
7
Gauge and Fault Monitoring
The open collector FAULT output provides a means for monitoring the status of the DS1510
to insure that all material passing between the probes is checked for doubles. When the DS1510
controller detects a fault from a probe or from within the controller itself, the FAULT output
turns OFF. Since the OFF state is the fault state, a loss of power at the DS1510 is, by default,
reported as a fault.
With firmware Version 3.6 and later, the FAULT output also turns off whenever the controller is
not in gauge mode, i.e. whenever the unit is in setup (SU) or calibration (CA) mode.

INSTALLATION AND SETUP
8
INSTALLATION
The installation of the components of the DS1510 system is covered in the following
paragraphs:
DS1510 Control Module
The control board is designed to mount on the back panel of an electrical enclosure using the four
mounting slots at the edges of the enclosure. The footprint is 8.25 inches (210 mm) by 6.25
inches (159 mm) with mounting slot locations on a rectangle 7.625 inches (194 mm) in the
horizontal and 4.0 inches (102 mm) in the vertical. Insure that the mounting screws make good
electrical contact between the module housing and the control enclosure back panel.
Avoid mounting locations with excessive heat and vibration.
Probe Mounting
See instructions specific to the probes supplied with your system.
Electrical Wiring
All wiring for the DS1510 connects to removable terminal blocks at the bottom of the control
enclosure as described in the following paragraphs.
1. Connect 100 to 240 VAC, 50-60 Hz. power (15 watts) to the terminals labeled AC on the
leftmost terminal block.
2. Connections to the control circuit of the machine are made through the OVER and UNDER
form C relays as required. These relays are powered in the NOMINAL condition and the
diagram on the DS1510 front panel reflects the NOMINAL state. As shipped from the
factory, the NOTHING state places the relays in the same state as NOMINAL. DIP switch
8, beneath the cover of the DS1510, when ON, causes the NOTHING condition to place the
OVER and UNDER relays in the over and under states simultaneously.
3. The shielded cables from the probes to the board should be run in conduit. The receiver
probe is connected to terminals labeled RCVR on the rightmost terminal block and the
transmitter probe to the terminals labeled TMTR on the same terminal block. Since the
probes are non-polarized, the order of lead connection is not important and since the probes
are identical, it does not matter which is the transmitter and which is the receiver. Connect
the shield leads (drain wires) from the probe cables to the terminals labeled SHLD.
4. The OVER and UNDER relays may be operated in a "follower" mode or a "memory" mode
depending upon the wiring of the RESET input. The operational modes and required
connections are described below.
a) For "follower" mode, jumper RESET and COM together on the center terminal block. In
this mode, when an OVER or UNDER condition occurs, the appropriate relay drops out,
and the OVER or UNDER LED comes on. After the fault condition is corrected, the relay
returns to the normally energized condition and the LED goes out. Automatic reset is
normally selected to control the operation when the fault condition is automatically
removed or the DS1510 is wired into the stop circuit of the machine.

INSTALLATION AND SETUP
9
b) For "latch" mode, wire the RESET and its associated COM terminal to the normally open
contacts of a switch, relay, or controller output. In this mode, when a fault condition
occurs, the relay drops out and the OVER or UNDER LED comes on. After the fault
condition is corrected, the contact must be momentarily closed to energize the relay.
5. If gap assess bypass is not selected (SW 5 OFF), a switch or contact may be connected
between AUXIN and COM to allow selection of two different calibration memories.
Calibration data is stored in the memory that is selected at the time calibration occurs.
Switching between calibration memories can be done at any time during DS1510 operation.
6. Optionally, the open collector FAULT output may be connected to a master system
controller or to an indicator that warns of error conditions within the DS1510 system. This
output is normally ON and turns OFF when an error condition is detected. Thus if the
DS1510 loses power, the FAULT output reports an error condition by default.
With firmware Version 3.6 and later (see Firmware Version at the end of this document),
the FAULT output turns OFF any time the DS1510 is not gauging the metal between the
probes. In addition to error conditions, setup (SU on the display) and calibration (CA on
the display) cause the fault output to turn OFF. This allows the unit to be monitored for
non-gauge conditions.
INITIAL SETUP
Probe and Gap Assessment
The startup process of the DS1510 commences immediately after power up and includes
several processes which are transparent to the user except for the sequence of characters that
appear on the two digit display.
When the unit first powers up, the several different sequences of characters may appear on the
two digit display depending upon which options are currently active. Typically, if probe gap
assessment is not bypassed, the startup display sequence includes momentary flashing of SU,
followed by momentary flashing of the probe identifier (PR 15, PR70, or PR 1H.), followed by
momentary display of the selected memory identifier, e.g. SL 01. When probe gap assessment is
bypassed (Switch 5 ON) the typical startup sequence includes momentary flashing of SU by,
followed by momentary flashing of the probe identifier, e.g. PR 70. If the probes are faulty,
disconnected, or cannot be identified, the controller flashes PR 01 indefinitely.
After the probes have been identified, the sensing system is characterized and the spacing
between the probes is determined. For this assessment there must be no material between the
probes. Switch 5 ON causes the controller to bypass this assessment unless a contact is closed
across AUXIN. However, it is essential that this process be completed at least once after
initial installation or whenever the physical arrangement of the probes is changed. If
assessment process is bypassed, the system flashes SU by on the two digit display during
startup.
When the operating conditions have been established, the two digit readout displays a numeric
value representing the receiver signal strength.

CALIBRATION
10
CALIBRATION
The DS1510 offers three modes of calibration: 1) manual calibration on single and double
material samples, 2) manual calibration on a single thickness material sample, and 3) automatic
calibration on material coming between the probes after a period of not material between the
probes.
Calibration on Single and Double Thickness
For highest gauging precision, the double sheet detector must be calibrated on both a single and
a double thickness of the material to be monitored, any time prior to running. This mode of
calibration is selected when Switch 3 is OFF. Calibration values are retained even when power
is removed from the DS1510. Depending upon selected options, the system can retain one or
two different calibration settings in non-volatile memory.
1. Place a single sheet of the thickness to be gauged in the probe gap and press the CAL push
button or close a contact across the external CAL input. If the calibration on single is
accepted, the unit displays alternately "CA" and "2" indicating readiness to calibrate on a
double thickness. If the calibration is not successful, the unit displays alternately "CE" and
a number. Calibration may be attempted again immediately.
2. Place a double thickness of material to be gauged in the probe gap and press the CAL push
button or close a contact across the external CAL input. If the calibration is successful, the
unit resumes display of the signal strength. If the calibration is not successful, the unit
displays alternately "CE" and a number. If this occurs, reinsert the single thickness and
begin calibration again.
Manual Calibration on Single Thickness
Manual calibration on single thickness is selected when Switch 3 is ON and Switch 6 is OFF. If
you change the switch settings, be sure to power the unit down and back up to activate the new
settings. The switches are read only at power-up.
When calibrate on single is selected, the calibration process may be triggered in two ways: by
the press of the front panel push button, or by a 30 millisecond or longer contact closure between
the external CAL input and COM.
Place a single sheet of the material to be gauged in the probe gap and press the CAL push
button or close a contact across the external CAL input. If the calibration on single is accepted,
the unit displays alternately "Fr" and a number indicating the frequency selected for operation.
The displayed number has no meaning except for factory troubleshooting.
If the control senses no material between the probes when the CAL push button is pressed or
the external CAL input is activated, it enters a wait state, flashing “CA” on the display until
material is brought between the probes. An additional calibration delay can optionally be
introduced through the calibration delay parameter (Cd). If not zero, this delay holds off the
calibration process for the specified delay time after material comes between the probes to
insure the material fully covers the probes during calibration. The additional delay may be
required with slow-moving material. See the Calibration Delay Time section later in this
document for the parameter adjustment procedure.

CALIBRATION
11
Gauging commences immediately after calibration but only if the push button is released and
the contact across CAL and COM is released. If either of the calibration initiating signals
persists, the unit hangs in a wait state.
Automatic Calibration on Single Thickness
Two switches must be properly set to enable automatic calibration. The system must be enabled
for calibrate on single (Switch 3 ON) and automatic calibration must be enabled (Switch 6 ON).
These switches must be set prior to powering the unit since they are read only at power-up.
Automatic calibration provides a time-based trigger that starts the calibration process. Whenever
there is no material between the sensing probes for a time equal to or greater than the stored
trigger interval (see Auto-cal Trigger Time later in this document), the DS1510 enters a wait
state in preparation for calibration when material comes between the probes. The display flashes
alternately “CA” and blank and the LEDs flash sequentially. The wait for material can be
indefinite.
When material enters the gap between the probes, if the calibration delay parameter (Cd) is set to
zero, calibration occurs within 100 milliseconds. For slow moving material, this delay can be
increased (up to 9.9 seconds) to insure the material fully covers the probes before calibration
occurs. With no programmed delay, typical calibration time is 300 milliseconds, total. See the
Calibration Delay Time section later in this document for the parameter adjustment procedure.
NOTE
The adjustable calibration delay parameter (Cd) is only available in systems with firmware
version 3.9 or higher. Older systems can be upgraded at the factory for a nominal fee. See
Firmware Version section later in this document for determining the firmware version of your
system.
If material comes between the probes before the trigger interval times out, the timer is reset to its
programmed value.
When automatic calibration is enabled, the calibration process may still be initiated by a press of
the CALIBRATE push button or a contact closure between CAL and COM. Actual calibration
will begin only when material is sensed between the probes and the calibration delay has timed
out..

CALIBRATION
12
The Auto-cal Trigger Time
The trigger time interval for automatic calibration can be set by the operator through the
CALIBRATE push button on the front panel of the DS1510 control unit. The interval is set in
increments of 6 seconds (0.1 minutes) from 0 to 3 minutes, in increments of 12 seconds (0.2
minutes) from 3 to 5 minutes, in increments of 30 seconds (0.5 minutes) from 5 to 10 minutes,
and in increments of 1 minute from 10 to 25 minutes. To set the trigger time interval, do the
following:
1. Insure that the unit is not attempting to calibrate (no “CA” flashing on the digital display). If
“CA” is flashing, place a piece of material between the probes and allow the calibration
process to be completed. Calibration and time parameter adjustment are mutually exclusive
processes.
2. Hold the CALIBRATE push button in for approximately 6 seconds or until “Ct” appears on
the digital display. WARNING: If the push button is released before 3 seconds, the DS1510
begins the calibration process.
3. When “Ct” displays, release the push button and the trigger time interval is displayed on the
digital readout. If the push button is not pressed again within 5 seconds, the display reverts
back to displaying gauge signal strength and the current time value is retained.
4. Whenever the time interval is displaying, the push button may be pressed to increment the
time to the desired value. The time value is incremented one resolution unit with every press
and release of the push button. If the push button is held in, the value auto-increments at an
ever increasing rate until the push button is released. The value increments up to a maximum
of 25 minutes and then rolls back to 0.1 minutes.
5. When the time has been adjusted to the desired value, it displays for 5 seconds (assuming the
push button is not pressed again) and then is accepted and saved in non-volatile memory.
The display reverts back to displaying signal strength.

CALIBRATION
13
Calibration Delay Time
The “Cd” parameter specifies the duration of a time delay that applies to single sample
calibration, in both manual and automatic trigger modes. The sequencing is as follows:
1. Calibration is triggered, either manually or through trigger time-out.
2. The system waits indefinitely until metal is detected between the probes.
3. When metal is detected, the calibration delay time-out begins.
4. When the calibration delay has timed out, calibration begins.
5. When calibration is complete, gauging begins.
The calibration delay interval can be set to any value between 0.0 and 9.9 seconds. To set the
calibration delay time, proceed as follows:
1. Insure that the unit is not attempting to calibrate (no “CA” flashing on the digital display). If
“CA” is flashing, place a piece of material between the probes and allow the calibration
process to be completed. Calibration and time parameter adjustment are mutually exclusive
processes.
2. Hold the CALIBRATE push button in for approximately 3 seconds or until “Cd” appears on
the digital display. If auto-cal is enabled, prior to displaying “Cd”, the DS1510 displays
“Ct”. WARNING: If the push button is released before 3 seconds, the DS1510 begins the
calibration process.
3. When “Cd” displays, release the push button and the calibration delay time interval is
displayed in seconds on the digital readout. If the push button is not pressed again within 5
seconds, the display reverts back to displaying gauge signal strength and the current delay
value is retained.
4. Whenever the time interval is displaying, the push button may be pressed to increment the
time to the desired value. The time value is incremented one resolution unit with every press
and release of the push button. If the push button is held in, the value auto-increments at an
ever increasing rate until the push button is released. The value increments up to a maximum
of 9.9 seconds and then rolls back to 0.0 seconds.
5. When the time has been adjusted to the desired value, it displays for 5 seconds (assuming the
push button is not pressed again) and then is accepted and saved in non-volatile memory.
The display reverts back to displaying signal strength.

SPECIFICATIONS
14
SPECIFICATIONS
Power Requirements
AC Power, 90 to 240 volts, 15 watts.
Logic Input Electrical Specifications
CAL, RESET, AUXIN: 30 Volts maximum
Upper switch threshold - 6.9 volts
Lower switch threshold - 3.3 volts
When the internal jumper is installed for pull up to accommodate sinking drivers, the input is
pulled to +15 volts through 4700 ohms. When the jumper is installed for pull down to
accommodate sourcing drivers, the input is pulled to common through 4700 ohms.
Logic Output Electrical Specifications
AUXO, FAULT: NPN open collector, 100mA max., 50 volts max.
Output Relay Specifications
Maximum switched voltage: 380VAC
Maximum switched current: 14 amps N.O., 5 amps N.C, AC resistive,
8 amps DC
Maximum switched power: 200W DC, 2,000VA AC.
Minimum required contact load: 12V, 100 mA
Expected mechanical life: 20 million operations
Expected electrical life: 100,000 operations at 8 amps, 240VAC
50,000 operations at 14 amps N.O., 5 amps N.C.,
120VAC resistive
30,000 operations at 7.2FLA, 45LRA, 120VAC
10,000 operations at 5FLA, 30 LRA, 240VAC

TROUBLESHOOTING
15
TROUBLESHOOTING
Should trouble develop, proceed as follows:
1. If no indicators or displays are illuminated, check AC input power to the control module
and the fuse located on the lower left of the chassis.
2. If the unit powers up but hangs displaying alternately “Pr” and “01”, the transmitter probe
is either not connected, is shorted, or has an open in the wiring.
3. If the unit powers up, initializes and the LEDs indicate a response to the material in the gap
but the relays do not switch, check that the relays are set to follow and not to latch (activate
the RESET input to unlatch). For most installations, simply install jumpers between
RESET and COM.
4. IF “PR” and “01” flash alternately on the display, check the transmitting probe for proper
connection and continuity.
5. IF “PR” and “02” flash alternately on the display, check the receiving probe for proper
connection and continuity.
6. IF “PR” and “03” flash alternately on the display, check both probes for proper connection
and continuity.
7. If the unit flashes alternately “Er” and a numeric value between 1 and 8, perform the
corrective action prescribed in the table below. If the error persists, consult the factory.
“Er” Number Fault Description Correction
01 Input shift register failure Reset through power down
02 Output shift register failure Reset through power down
03 Display shift register failure Reset through power down
04 Control shift register failure Reset through power down
05 System configuration data fault Reset through power down
06 Gap assessment data fault Execute gap assess procedure
07 Not used
08 Processor CONFIG register fault Call the factory
8. During manual calibration on single and double, errors may occur that are reported through
the alternate display of “CE” and a numeric value of 1 or 2. These error codes have the
following meanings:
“CE” Number Interpretation
01 The single thickness material is too thin for the system as
configure with the current probes.
02 The material is too thick for the system as configured with
the current probes.

TROUBLESHOOTING
16
Firmware Version
From time to time, as improvements are made to Prime products, the firmware controlling the
units is revised. When setting a unit up or troubleshooting it may be necessary to determine the
version number for the firmware installed in your unit. The version numbers begin with 1.0 and
are incremented either by tenths (1.1, 1.2, etc.) for small revisions or by the integer digit (1.0, 2.0,
etc.) for more significant revisions.
To determine the version of the firmware running in your unit, simply hold the calibration push
button in as power is applied to the unit. The revision number will be displayed on the two-digit
display alternately with the letters “Fr”. For example, Version 1.8 will flash alternately “Fr” and
“1.8”.
For further information or service assistance, contact Prime Controls, Inc., 4551 Gateway
Circle, Dayton, Ohio. Phone: [phone]. Mention model number and serial number.

17
CONTROL I/O PROBES
SIGNAL/MESSAGE
MESSAGES
Pr 01 flashing -
Transmitter Probe Fault
Receiver Probe Fault
Pr 02 flashing -
Pr 03 flashing -
Both Probes Faulting
CA - Calibration Mode
CA nn flashing -
Calibration Fault
Er nn flashing -
Fatal System Fault
DS1510
DOUBLE SHEET DETECTOR
NOMINAL
UNDER
OVER
GAP
AC AC
POWER OVER UNDER
RELAY RELAY
CAL COM RCVR RCVR SHLD SHLD TMTR TMTR RESET COM
AUXIN
COM AUXO COM
FAULT
COM
100 - 240 AC OUTPUTS
INPUTS
CALIBRATE
PRIME
CONTROLS, INC.

(1.31)
193.7
(7.625)
209.6
(8.25)
101.6
(4.0)
28.6
(1.125)
33.3
(0.60)
15.2
158.8
(6.25)

18
3. MAINTAIN INDEPENDENT SHIELDS
4. POSITION SHIELD TERMINALS BETWEEN
TRANSMITTER AND RECEIVER SIGNAL
TERMINALS
TRANSMITTER
RECEIVER
TRANSMITTER
RECEIVER
FOR MAXIMUM NOISE IMMUNITY, SPLICE
OR TERMINATE CABLES ONLY WHEN
ABSOLUTELY NECESSARY.
WHERE EXTENSION IS NECESSARY,
USE BELDEN 8761 OR EQUIVALENT
SHIELDED, TWISTED PAIR CABLE.
THE DS1510 IS DESIGNED TO PROVIDE
HIGH COMMON MODE NOISE REJECTION.
COMMON MODE REJECTION IS REALIZED
MOST EFFECTIVELY WITH TWISTED PAIR
CABLING.
TO PROBES
SAFETY GND
AC POWER
CONTROL
INTERLOCK
OPEN FOR DOUBLE
CONTROL
INTERLOCK
OPEN FOR UNDER
OPTIONAL
REMOTE CAL
OPTIONAL
OUTPUT LATCH RESET
JUMPER SOLID IF LATCHING
OUTPUT NOT DESIRED
FAULT SIGNAL
NPN, OPEN COLLECTOR
100 mA MAX., OFF = FAULT
HOOKUP IS OPTIONAL
NPN, OPEN COLLECTOR, 100 mA MAX.
OFF FOR OVER OR UNDER, NO DELAY.
FAST RESPONSE OUTPUT
CONTROL I/O PROBES
SIGNAL/MESSAGE
MESSAGES
Pr 01 flashing -
Transmitter Probe Fault
Receiver Probe Fault
Pr 02 flashing -
Pr 03 flashing -
Both Probes Faulting
CA - Calibration Mode
CA nn flashing -
Calibration Fault
Er nn flashing -
Fatal System Fault
DS1510
DOUBLE SHEET DETECTOR
NOMINAL
UNDER
OVER
GAP
AC AC
POWER OVER UNDER
RELAY RELAY
CAL
COM
RCVR
RCVR SHLD
SHLD
TMTR TMTR
RESET COM
AUXIN
COM
AUXO COM
FAULT
COM
100 - 240 AC OUTPUTS
INPUTS
CALIBRATE
PRIME
CONTROLS, INC.

MEMORY SELECT or
GAP ASSESS BYPASS
OPTIONAL

19
LIMITATION AND EXCLUSION OF WARRANTIES
All goods purchased from Prime Controls, Inc. shall be free from defects in materials, design and
workmanship under normal conditions of use for one year from the date of shipment. THIS
WARRANTY IS THE SOLE WARRANTY AND IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTY OF MERCHANTABILITY OF FITNESS FOR A PARTICULAR
PURPOSE. THE LIABILITY OF PRIME CONTROLS TO ANY PURCHASER SHALL BE
LIMITED EXCLUSIVELY TO THE COST OF REPLACEMENT OR REPAIR OF
DEFECTIVE PARTS, AND SHALL NOT INCLUDE LIABILITY FOR ANY DIRECT,
CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER, WHETHER
FORESEEN OR UNFORESEEN, INCLUDING BUT NOT LIMITED TO LOST PROFITS,
LOST SALES, OR INJURY TO PERSONS OR PROPERTY. 10/03/19