Prime Controls DS600 User manual

DS600 Non-Ferrous Double Sheet Detector
Operating Instructions
202177 Revision M
01/14/2020
Prime Controls, Inc.
DESCRIPTION
The Model DS600 Double Sheet Detector control module and P80T30P probe comprise a
system designed to differentiate a wide range of material thicknesses for non-ferrous metals.
This system is especially suited for, but not limited to, the detection of single and double
thicknesses of aluminum and 300 series stainless steel (single/double sensing) and detection of
missing components (part present sensing).
The control module is housed in an IP65 rated, industrial grade polycarbonate enclosure that
can be mounted either inside a control panel or in the open. The P80T30P probe is in the form
of a 30mm threaded plastic barrel.

DS600 Non-Ferrous Double Sheet Detector
This document is confidential and proprietary. No part of this document may be disclosed in any manner
to a third party without the prior written consent of Prime Controls, Inc.
202177 i Revision M
Revision History
Revision Date Description Author
G 2017-01-23 Change bracket part number from BR30AN to BR30PL,
added Aluminum distance graph and ranges. RMC
H 2017-01-31 Added Stainless Steel distance graph and ranges. RMC
I 2017-02-20 Added ModBus physical and electrical characteristics. RMC
J 2017-12-21 General clean up and clarification. V1.07 software release. RMC
K 2019-02-12 Corrected error in LTol default value. V1.10 software release
and SW8 reference to Modbus termination. Added wire
colors to Table 8. Corrected company address.
RMC
L 2019-03-13 V1.11 software release. Corrected operation of Modbus
Read Multiple Registers command (FN06). Increased
tolerance for Probe Disconnect detection. Calibrate
algorithm enhancement. Reject output off during device turn
on.
RMC
M 2020-01-14 Added recommended Htol settings for single point
calibration on aluminum and 300 series stainless steel. JAM
©Prime Controls, Inc.

DS600 Non-Ferrous Double Sheet Detector
This document is confidential and proprietary. No part of this document may be disclosed in any manner
to a third party without the prior written consent of Prime Controls, Inc.
202177 ii Revision M
Table of Contents
1SYSTEM COMPONENTS....................................................................1
1.1 Control Module ..................................................................................................1
1.2 Probe.................................................................................................................2
1.3 Probe Nose........................................................................................................2
1.4 Brackets.............................................................................................................2
1.5 Cables................................................................................................................2
1.5.1 High Flex....................................................................................................2
1.5.2 Bulk Cable .................................................................................................3
2INSTALLATION...................................................................................4
2.1 Controller Mounting............................................................................................4
2.2 Probe Mounting and Positioning........................................................................4
2.3 Logic I/O Wiring.................................................................................................4
2.4 Input Logic Signals.............................................................................................7
2.4.1 IN REF, SEL REF......................................................................................8
2.5 Output Logic Signals..........................................................................................8
2.5.1 OUT REF...................................................................................................9
2.6 Modbus Configuration (DS600PC Only)............................................................9
2.7 DIP Switch Settings ...........................................................................................9
3Operation..........................................................................................10
3.1 Power-Up Sequence........................................................................................10
3.2 User Interface..................................................................................................10
3.3 Pushbutton Operation......................................................................................10
3.3.1 Initiating One-Point or Two-Point Calibration...........................................10
3.3.2 Changing Parameter Values....................................................................10
3.4 Front Panel Display..........................................................................................11
3.5 Calibration........................................................................................................11
3.5.1 One-point Calibration for Single/Double Sensing.....................................12
3.5.2 Two-point Calibration for Single/Double Sensing.....................................12
3.5.3 One-point Calibration for Part Present Sensing.......................................13
3.5.4 Two-point Calibration for Part Presence Sensing....................................13
3.6 Calibration Save and Recall.............................................................................14
3.7 Setup Considerations.......................................................................................15

DS600 Non-Ferrous Double Sheet Detector
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to a third party without the prior written consent of Prime Controls, Inc.
202177 iii Revision M
3.8 Gauging Response..........................................................................................15
4MODBUS COMMUNICATION (DS600PC Only)...............................18
4.1 Serial Interface.................................................................................................18
4.2 Commands ......................................................................................................18
4.2.1 Discrete Coil Outputs (000001)................................................................19
4.2.2 Discrete Coil Inputs (100001) ..................................................................19
4.2.3 Register Inputs (300001) .........................................................................20
4.2.4 Holding Registers (400001).....................................................................21
4.3 Calibration Data Backup and Restore..............................................................22
5TROUBLESHOOTING.......................................................................23
6GAUGING SPECIFICATIONS...........................................................25
7ELECTRICAL SPECIFICATIONS .....................................................27
8MECHANICAL SPECIFICATIONS....................................................28
8.1 Controller Drawing...........................................................................................28
8.2 Probe Drawing.................................................................................................29
9LIMITATIONS AND EXCLUSION OF WARRANTIES.......................30

DS600 Non-Ferrous Double Sheet Detector
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to a third party without the prior written consent of Prime Controls, Inc.
202177 1 Revision M
1 SYSTEM COMPONENTS
1.1 Control Module
The DS600 control module, being sealed, offers flexibility in mounting. Once installed, the
system can be quickly and easily brought on-line. Calibration is achieved through the simple
press of a push-button switch on the front panel or a remote contact closure connected to the
CAL terminal. System status and faults are reported on a four digit numeric display and are
signaled through the FAULT output that may be connected to a PLC or system controller.
The DS600 control module comes in three variations which differ in available features. The
three variations are designated DS600 (basic), DS600P, and DS600PC. All variants share a
common footprint and utilize the P80T30 probe. All models offer the following features:
•Sealed polycarbonate enclosure
•Four digit digital display
•LED indicator for ACCEPT
•LED indicator for REJECT
•User selection of the gauging mode, single/double or part present
•User selection of the response to a no-metal condition, REJECT or ACCEPT
•Front panel pushbutton switch to invoke calibration and parameter adjustment
•Isolated sinking or sourcing logic inputs, CAL and RESET
•Remote initiation of calibration through the CAL input
•Remote reset of the latched REJECT output through the RESET input
•Isolated sinking or sourcing logic outputs, ACCEPT, REJECT, FAULT and AUX
•One and two point thickness calibration
•At least one non-volatile calibration memory
•Single/Double gauging tolerance parameter HtoL, adjustable through the front panel
•Part present gauging tolerance parameter toL, adjustable through the front panel
The DS600P control module offers these additional features:
•“Under” condition sensing with tolerance set through parameter Ltol
•Delay of under condition reporting through delay parameter Udly
•Up to eight non-volatile calibration memories
•Selection of up to 8 calibration memories through the front panel parameter SEL (1-8)
•Logic inputs SEL0, SEL1, SEL2, and ENABLE for selection of the calibration memory
from a remote switch or controller
The DS600PC control module offers these added features:
•Up to 64 non-volatile calibration memories
•Selection of up to 64 calibration memories through the front panel parameter SEL (1-64)
•Selection of the first eight calibration memories through terminals SEL0, SEL1, SEL2
and ENABLE
•Modbus communications through an M12 connector providing access to:
oThe DIP switch settings
o64 calibration memories, select and read-back
oThe gauging signal value
oThe four digit display information as text

DS600 Non-Ferrous Double Sheet Detector
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202177 2 Revision M
oThe gauging upper and lower tolerance values
oThe gauging threshold values (single/double threshold and under/single
threshold)
oThe no-metal threshold value (no-metal/metal present threshold)
oAll calibration values
oCommunication statistics
•Specification of the Modbus node number through the front panel parameter Id
•Installation of the network terminator through a switch setting
1.2 Probe
The DS600 family currently supports the Prime Controls’ 30mm non-ferrous metal P80T30P
probe. The connection between the controller and the probe uses an industrial Ethernet cable
with 4 twisted wire pairs terminated on one end in a female M12 8 pole connector. The
maximum combined length of cables between the probe and controller is 30m.
The probe is in the form of a 30mmx1.5 threaded plastic body 70mm long not including the
connector (see page 29).
1.3 Probe Nose
The P80T30P probe may be used with the AC30N Delrin probe nose to protect the sensor nose
from potential impact damage. The nose is 2mm thick at the probe face.
1.4 Brackets
The P80T30P probe may be used with the following brackets:
•BR30PL Compliant (spring) mount, plastic
•BR30PA Straight, adjustable point, plastic
•BR30PS Straight, clamp, plastic
1.5 Cables
1.5.1 High Flex
The following high flex cables are available for connecting the P80T30P probe to the DS600
controller:
•CBL600-5 5m high flex cable
•CBL600-15 15m high flex cable
To realize the rated flex life of the cable (10 million cycles), the bend radius of the cable in
continuous flex applications must be 150mm (6 inches) or greater. Smaller radii may result in
reduced flex life.
Additional cable length may be added to the standard cable length up to 30m total distance from
the probe to the controller.

DS600 Non-Ferrous Double Sheet Detector
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to a third party without the prior written consent of Prime Controls, Inc.
202177 3 Revision M
1.5.2 Bulk Cable
Bulk cable may be used between the probe, CBL600-X cable and the controller when additional
length is needed up to 30m (100ft) total length. Cable may be ordered as 202324-X, where X is
the desired cable length in feet. Cables may be spliced using conventional techniques or
terminal strips. Color coding should be maintained across any splices to ease installation and
repairs if ever necessary. The untwisted, unshielded lead length at the splice should be kept to
a minimum. Bulk cable is not rated for continuous flex. If continuous flex is required, please
contact Prime Controls.

DS600 Non-Ferrous Double Sheet Detector
This document is confidential and proprietary. No part of this document may be disclosed in any manner
to a third party without the prior written consent of Prime Controls, Inc.
202177 4 Revision M
2 INSTALLATION
2.1 Controller Mounting
The controller is surface mounted by four 0.172” diameter mounting holes located in the corners
of the case that are sized for screws as large as #8. They are located on a rectangle 159mm x
121mm (6.26” x 3.58”). The depth of the case at the mounting holes is 0.120”. The mounting
holes are accessed by removing the four screws that retain the clear cover of the controller.
The Controller can operate in any orientation however, for ease of use, it is best to orient the
unit with the display and text right side up. The case is IP65 rated so the unit may be mounted
inside or outside of a protective cabinet. Take care that the cable pathways may affect the unit’s
ability to fully prevent the ingress of liquids. See Mechanical Specifications on page 28 for full
details.
2.2 Probe Mounting and Positioning
The P80T30P probe must be mounted using non-metallic materials such as Delrin to insure the
mounting hardware does not interfere with the sensing of the target material. No metal should
come within half the probe diameter (15mm) of the sides of the probe.
The distance from the P80T30P probe face and the material sample can range from direct
contact to as much as ½ inch, depending upon the metal thickness. However, whatever the gap,
for proper operation the separation distance must be held constant between gauging and
calibration.
2.3 Logic I/O Wiring
The logic inputs and outputs of the DS600 family of controllers are electrically isolated from the
controller circuitry. However, the integrity of the isolation and the type of signal (sourcing or
sinking) for a particular application are determined by the connections made to the reference
lines IN REF, SEL REF, and OUT REF.
For a given signal type, e.g. sourcing or sinking, the reference signals for inputs and outputs are
opposite. For sourcing signals, the input reference is connected to common and the output
reference is connected to the power supply high side. Conversely, for sinking signals, the input
reference is connected to the power supply high side and the output reference is connected to
common.
Additional +24V and COM terminals are available on the DS600 family controllers to facilitate
appropriate connections to the reference inputs if isolation is not required. If isolation is required,
the power supply common and high side of the isolated supply (perhaps power supply powering
the PLC connected to the DS600 controller) must be connected to the appropriate reference
terminals.
Just as it is possible to mix sourcing and sinking between the INP, OUTPUTS, and CAL MEM
groups of signals, it is also possible to mix isolated and non-isolated operation between these
same three groups.
In further discussions in this manual, the terms common and +24V will be used to signify power
common and high side respectively. These same terms will be used regardless if these
potentials are isolated or not from the power used to supply the controller, i.e. if isolation is
desired or not.

DS600 Non-Ferrous Double Sheet Detector
This document is confidential and proprietary. No part of this document may be disclosed in any manner
to a third party without the prior written consent of Prime Controls, Inc.
202177 5 Revision M

DS600 Non-Ferrous Double Sheet Detector
This document is confidential and proprietary. No part of this document may be disclosed in any manner
to a third party without the prior written consent of Prime Controls, Inc.
202177 6 Revision M
Table 1
Signal Group
Driver Signal Type
Non Isolated
Sourcing
Non Isolated
Sinking
Isolated
Sourcing
Isolated
Sinking
INP (input)
Controller
Common
Controller
+24V
Isolated
Common
Isolated
+24V
CAL MEM
Controller
Common
Controller
+24V
Isolated
Common
Isolated
+24V
OUTPUTS
Controller
+24V
Controller
Common
Isolated
+24V
Isolated
Common

DS600 Non-Ferrous Double Sheet Detector
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2.4 Input Logic Signals
The logic inputs to the DS600 family of controllers include the four signals for selecting the
calibration memory (SEL0-3 and ENABLE), an external calibration input (CAL) and an output
latch RESET signal. All inputs are electrically isolated from the controller circuitry but may
optionally be made to share common or power supply voltage with the controller.
All logic inputs may be configured to receive signals from sourcing or sinking drivers. To receive
sourcing signals, connect the reference signals (IN REF and SEL REF) to common. To receive
sinking signals, connect the reference signals to the +24V power supply voltage.
CAL
The CAL terminal provides a means of initiating calibration of the DS600 without having to
access the front panel pushbutton. When a pulse is applied to the CAL terminal, high for
sourcing, low for sinking, the calibration process is initiated. To be detected by the controller,
the pulse must be ON for a minimum of 25 milliseconds. See Calibration section (page 11) for
modes of calibration.
RESET
The RESET signal controls the latch feature on the REJECT output signal. If RESET is applied,
high for sourcing, low for sinking, the REJECT output simply follows the state of the gauge
signal. If RESET is not applied and the gauge signal moves into the reject range, the RESET
signal switches to the OFF state and remains there indefinitely until the gauge signal moves out
of the reject range and RESET is applied.
This feature allows fast REJECT signals to be captured and held until acknowledged by either a
return signal from a controller or a manual reset by an operator.

DS600 Non-Ferrous Double Sheet Detector
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202177 8 Revision M
To avoid the REJECT output being latched in the REJECT state, a jumper must be installed
from the RESET terminal to +24V if sourcing I/O is selected or to COM if sinking I/O is selected.
SEL2, SEL1, SEL0, ENABLE
The SEL2-0 and ENABLE terminals are active for the DS600P and DS600PC controllers. These
inputs select between one of eight possible stored calibration memories as described in the
Calibration section (page 11).
2.4.1 IN REF, SEL REF
The IN REF terminal is connected to either common or +24V based on the type of drivers
driving the CAL and RESET inputs. If the drivers are sourcing, then connect IN REF to common.
Conversely, if the drivers are sinking, connect IN REF to +24V. Because IN REF is common to
both CAL and RESET, the driver connected to each must be of the same type.
The SEL REF terminal is connected to either common or +24V based on the type of drivers
driving the SEL0-SEL2 and ENABLE inputs. If the drivers are sourcing, then connect SEL REF
to common. Conversely, if the drivers are sinking, connect SEL REF to +24V. Because SEL
REF is common to SEL0-2 and ENABLE, the driver connected to each must be of the same
type.
2.5 Output Logic Signals
The controller has four logic outputs for reporting the results of the
gauging operation and the state of the system. The four outputs are
electrically isolated from the internal controller circuitry and the inputs
but share a common reference signal: OUT REF. If the outputs are to
be sinking, connect OUT REF to common. Conversely, if the outputs
are to be sourcing, connect OUT REF to +24V.
Each output is protected from over-voltage by a 30 volt bidirectional
transient suppressor and is fused at 50 milliamps by a self-resetting
fuse.
ACCEPT
This signal is asserted whenever the gauging logic indicates an
acceptable thickness of metal before the probe for double/single
sensing, or the acceptable presence of a part for part present sensing.
See Tables 5-7 for gauging logic outcomes.
REJECT
The logic of the REJECT signal is implemented to provide failsafe operation. This means the
output turns OFF to report a reject condition. Therefore, if the controller loses power, a reject
condition is automatically reported. The REJECT output turns OFF if a double is detected for
single/double sensing or if a part is found to be missing for part present sensing. Optionally, as
determined by the setting of DIP switch 2, a no-metal condition may be reported as a REJECT.
See Tables 5-7 for gauging logic outcomes.
FAULT
Like the REJECT output, the FAULT output is implemented to provide failsafe operation. When
there is no fault to be reported, the output is ON so that a loss of power to or failure of the
controller is more likely to report a fault. The source of faults may be:

DS600 Non-Ferrous Double Sheet Detector
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to a third party without the prior written consent of Prime Controls, Inc.
202177 9 Revision M
•A disconnected probe
•A failed probe
•An internal controller error
AUX
The AUX output is enabled when switch 3 is ON, to report an UNDER condition, namely, a
material condition significantly thinner than the calibrated nominal thickness. Like the REJECT
and FAULT outputs, this signal is implemented to provide failsafe operation; the signal turns
OFF to report an under condition.
2.5.1 OUT REF
The OUT REF terminal is connected to either common or +24V depending upon the type of
output desired for ACCEPT, REJECT, FAULT, and AUX. If sourcing drivers are desired,
connect OUT REF to +24V. Conversely, if sinking drivers are desired, connect OUT REF to
common. Because OUT REF is common to all outputs, all outputs must be the same type.
See Installation (page 4) of this document for further details.
2.6 Modbus Configuration (DS600PC Only)
Prior to using Modbus communication, the unit’s Modbus ID and Modbus Termination DIP
switch (sw8) should be set as required according to the DIP Switch Settings and Changing
Parameter Values sections elsewhere in this document.
2.7 DIP Switch Settings
Table 2
SWITCH FUNCTION OFF ON
1
Sensing Type1
Single/Double
Part Present
2
Reject on No Metal
No
Yes
3
Aux Output
Disabled
Reports Under
4
Reserved
Set to OFF
5
Reserved
Set to OFF
6
Reserved
Set to OFF
7
Reserved
Set to OFF
8
Modbus Termination
Disabled
Enabled
1Changing the state of this switch will prompt for a recalibration.

DS600 Non-Ferrous Double Sheet Detector
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202177 10 Revision M
3 Operation
3.1 Power-Up Sequence
When the system first powers up, the model designation scrolls across the digital display
several times identifying the controller as a dS 600, a dS 600P, or a dS 600PC. After displaying
the model number, the controller displays the probe ID by flashing alternately, for two seconds,
the letters Prb and the number 0indicating the P80T30 probe is connected and functioning. If
no probe is connected or the connected probe fails to communicate with the controller, the
display flashes alternately the letters PFlt and the number 1.
For the DS600P and DS600PC models, a third value is then displayed, the numeric address of
the currently selected calibration memory. The display flashes alternately for several seconds,
SEL and the current calibration memory address.
For all models, if the calibration memory selected at power up holds valid calibration data, the
controller transitions to displaying the gauge value, a number from 0 to 100. If the calibration
memory does not hold valid calibration data, the controller displays alternately the letters nEEd
and CAL until valid calibration data is saved in the selected memory. Successful execution of
the calibration function for the selected memory clears this message and allows the gauge value
to be displayed.
If the controller is power cycled while displaying nEEd and CAL, default calibration parameters
are installed at power up and the controller precedes to display the gauge value.
3.2 User Interface
Operation of the DS600, DS600P and DS600PC systems involves calibration and parameter
adjustment using the front panel pushbutton, and message interpretation. Calibration may be
based on data collected for a single point or on data collected from two points as detailed below
under Calibration.
3.3 Pushbutton Operation
The push-button switch on the front panel of the control module serves to initiate the calibration
process and to make parameter adjustments for system setup.
3.3.1 Initiating One-Point or Two-Point Calibration
A single, quick press and release of the pushbutton initiates one-point calibration. Two
successive quick presses of the pushbutton initiates two-point calibration. See the section on
Calibration (page 11).
3.3.2 Changing Parameter Values
To view the current value of a parameter, press the pushbutton and hold it for more than 3
seconds until the appropriate parameter identifier (HtoL), or if available, (SEL), (Ltol), (Udly) or
(Id) appears on the digital display. While the pushbutton is pressed, the display cycles through
the identifiers with each one shown on the display for one and a half seconds. While the
desired parameter identifier is showing on the display, release the pushbutton and the current
value of the parameter displays for 5 seconds. To retain the current value of the parameter,

DS600 Non-Ferrous Double Sheet Detector
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202177 11 Revision M
simply allow the 5 second display interval to elapse. The display reverts to displaying the gauge
signal with no change to the parameter.
To change the value of a parameter, press the pushbutton and hold it for more than 3 seconds
until the appropriate parameter identifier appears on the digital display. While the desired
parameter identifier is showing on the display, release the pushbutton and the current value of
the parameter displays. Press and hold the pushbutton while the parameter value is displaying
and the value increments, first slowly then more rapidly. For more precise control of the value
adjustment, simply tap the pushbutton 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 while the
new value is displaying. The display reverts to displaying gauge signal strength.
Table 3
Parameter Full Name Function Range
[Default] Controller Type
SEL
Memory
Selection
Select calibration memory
1-7 [1]
P only
SEL
Memory
Selection
Select calibration memory
1-64 [1]
PC only
HtoL
High Tolerance
Set high tolerance
percentage
0-100 [50]
All
LToL
Low Tolerance
Set low tolerance
percentage
0-100 [100]
P and PC
toL
High Tolerance
(Part Present)
Set high tolerance
percentage
0-100 [50]
All in Part
Present Mode
Udly
Under Delay
Set “under” reporting delay
(hundredths of a second)
0-200 [0]
P and PC
Id
ModBus ID
Set the ModBus Unit ID
1-32 [0]1
PC only
1Modbus ID defaults to an illegal value requiring the installer to select an appropriate value for
their network.
3.4 Front Panel Display
The four digit 7 segment front panel display continuously displays the current gauge value from
0 to 100. A nominal value of 50 is displayed for metal thicknesses equal to the calibration
thickness. When not gauging, the display is used to show user prompts, status, and error
messages for the controller.
3.5 Calibration
The DS600 supports two modes of calibration, referred to here as one-point and two-point
calibration. One-point calibration requires only one sample of material of nominal thickness. Two
point calibration requires two samples of the nominal thickness material. Two-point calibration is
the most accurate and repeatable calibration method and is recommended.

DS600 Non-Ferrous Double Sheet Detector
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3.5.1 One-point Calibration for Single/Double Sensing
To perform a single/double one-point calibration:
1. For DS600P and DS600PC controllers, select the desired memory location for the
calibration (See Calibration Save and Recall, page 14)
2. Place a single thickness of the sample material in front of the probe face.
3. Press and release the CALIBRATE pushbutton once or apply a single momentary signal
to the external CAL terminal. The display alternates CAL and Pnt1 until calibration is
complete.
The gauging thresholds are computed as an offset from the signal value captured during
calibration. The size of the offset is computed as a percentage of the gauge value at Pnt1. The
threshold computations are:
Single/Double Threshold = (Cal Pt Value) x (1 + Htol/100)
Under Threshold = (Cal Pt Value) x (1 – Ltol/100)
The tolerances Htol and Ltol, expressed in percent, may be adjusted through the front panel as
parameters Htol and Ltol respectively. The Htol setting defaults to 50%. However, for greatest
reliability in sensing doubles over the thickness range of 0.001” (0.025mm) to 1.14” (3.5mm),
the settings specified in the table below are recommended.
Material & Thickness Range Htol Setting for Double Discrimination
Al .001” (.025mm) through .040” (1.0mm) 40%
Al .041” (1.1mm) through .100” (2.54mm) 20%
Al greater than .100” (2.54mm) 15%
Stainless Steel .001” (.025mm) through 1.40” (35.5mm) 30%
Ltol defaults to 100%. When Ltol is set to 100%, under gauging is disabled.
Under tolerance checking is available in the DS600P and DS600PC only.
3.5.2 Two-point Calibration for Single/Double Sensing
To perform a single/double two-point calibration:
1. For DS600P and DS600PC controllers, select the desired memory location for the
calibration (See Calibration Save and Recall, page 14)
2. Place a single thickness of the sample material in front of the probe face.
3. Quickly press and release the CALIBRATE pushbutton twice within one second or apply
two momentary signals to the external CAL terminal. The display alternates CAL and
Pnt1.
4. Wait for the display to change to CAL and Pnt2 then add a second material sample in
front of the probe face and press and release the CALIBRATE pushbutton or apply a
momentary signal to the external CAL terminal.

DS600 Non-Ferrous Double Sheet Detector
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5. If the calibration is successful, the display reverts to displaying the gauge signal and
calibration is complete
6. If the material is too thick or if the thickness measured at point 2 is very near to the
thickness measured at point 1, the display alternates showing Lo and diFF. To recover
from this condition, follow steps 6 or 7 below.
7. Restart calibration by placing a single thickness sample before the probe and press the
CALIBRATE pushbutton once or momentarily assert external CAL. Go to step 3.
8. Wait 30 seconds and the DS600 reverts to its previous state of gauging.
The gauging thresholds are computed as offsets from the first calibration point value. For the
single/double threshold, the offset is added to Pt1 placing it between the Pt1 and Pt2 values.
The under offset is subtracted from the Pt1 value placing it below the Pt1 value. The size of the
offset is computed as a percentage of the distance from the first calibration point to the second
calibration point. The upper threshold computation is:
Single/Double threshold = Pnt1 + (Pnt2 – Pnt1) x Htol/100
Under threshold = Pnt1 – (Pnt2 – Pnt1) x Ltol/100
The tolerances Htol and Ltol, expressed in percent, may be adjusted through the front panel as
parameters Htol and Ltol respectively. The defaults for these tolerances are 15% for Htol and
100% for Ltol. When Ltol is set to 100%, under gauging is disabled.
Under tolerance checking is available in the DS600P and DS600PC only.
3.5.3 One-point Calibration for Part Present Sensing
To perform a part present one-point calibration:
1. For DS600P and DS600PC controllers, select the desired memory location for the
calibration (See Calibration Save and Recall, page 14)
2. Place the ”part missing” condition (the thinner material) in front of the probe face.
3. Press and release the CALIBRATE pushbutton once or apply a single momentary signal
to the external CAL terminal. The display alternates CAL and Pnt1 until calibration is
complete.
The gauging threshold is computed as an offset from the signal value captured during
calibration. The size of the offset is computed as a percentage of the gauge value at Pnt1. The
threshold computation is:
Threshold = (Cal Pt Value) x (1 - Tol/100)
The tolerance (Tol), expressed in percent, may be adjusted through the front panel as
parameter toL. The default value for single point calibration is 15%.
3.5.4 Two-point Calibration for Part Presence Sensing
To perform a part present two-point calibration:
1. For DS600P and DS600PC controllers, select the desired memory location for the
calibration (See Calibration Save and Recall, page 14)
2. Place a sample of the “part missing” material condition in front of the probe face.

DS600 Non-Ferrous Double Sheet Detector
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to a third party without the prior written consent of Prime Controls, Inc.
202177 14 Revision M
3. Quickly press and release the CALIBRATE pushbutton twice within one second or apply
two momentary signals to the external CAL terminal. The display alternates CAL and
Pnt1.
4. Wait for the display to change to CAL and Pnt2 then place a sample of the part present
condition in front of the probe face and press and release the CALIBRATE pushbutton or
apply a momentary signal to the external CAL terminal.
5. If the calibration is successful, the display reverts to displaying the gauge signal and
calibration is complete.
6. If the material is too thick or if the thickness measured at point 2 is very near to the
thickness measured at point 1, the display alternates showing Lo and diFF. To recover
from this condition, follow steps 6 or 7 below.
7. Restart calibration by placing a sample of the “part missing” condition before the probe
and press the CALIBRATE pushbutton once or apply a momentary signal to the CAL
terminal. Go to step 3.
8. Wait 30 seconds and the DS600 reverts to its previous state of gauging.
The gauging threshold is computed as an offset from the first point value in the direction of the
second point value. The size of the offset is computed as a percentage of the distance from the
first point to the second. The threshold computation is:
Threshold = Pnt1 - (Pnt2 - Pnt1) x Tol/100
The tolerance (Tol), expressed in percent, may be adjusted through the front panel as
parameter toL. The default value is 15%.
3.6 Calibration Save and Recall
After successful calibration, the DS600 saves the calibration in non-volatile memory. Model
DS600 saves only one calibration dataset. Model DS600P can save up to eight different
calibrations, and model DS600PC can save up to 64 different calibrations. Where multiple
calibrations can be saved, each saved calibration must be uniquely identified for later retrieval.
The identifier is in the form of a number ranging from 1 to 8 for the DS600P and from 1 to 64 for
the DS600PC.
The DS600P calibration identifier (1-8) may be specified through the front panel SEL parameter
or through the signals applied to the SEL2 through SEL0 and ENABLE terminals (See Table 4).
Whenever the ENABLE signal is asserted (ON), the selected calibration is determined by the
signals applied to the SEL2 through SEL0 terminals. When ENABLE is not asserted (OFF), the
selected calibration is determined by the last memory address entered through the front panel
SEL parameter.
Table 4
SEL2 SEL1 SEL0
MEMORY
NUMBER
OFF
OFF
OFF
1
OFF
OFF
ON
2
OFF
ON
OFF
3

DS600 Non-Ferrous Double Sheet Detector
This document is confidential and proprietary. No part of this document may be disclosed in any manner
to a third party without the prior written consent of Prime Controls, Inc.
202177 15 Revision M
The DS600PC calibration identifier may come from
any of three sources, 1) the SEL parameter entered
through the front panel If ENABLE is not asserted, 2)
through the SEL0, SEL1 and SEL2 terminals if
ENABLE is asserted, or 3) through the network via
the Modbus port if ENABLE is not asserted.
Terminals SEL0 through SEL2 always have priority if
ENABLE is asserted. When ENABLE is not asserted
the selected calibration is the last one entered either
through the front panel or from the network. Thus, if ENABLE is OFF, the latest entry, whether
from the front panel SEL parameter or the network, determines the memory selection.
If the selected calibration memory does not contain valid calibration data, the system reports the
need for calibration by alternately displaying nEEd and CAL until a valid calibration is
completed or another calibration memory is selected
See Logic Inputs (page 6) for electrical implementation of the SEL0, SEL1, SEL2 and ENABLE
signals.
3.7 Setup Considerations
For most applications, sensing an “under” condition is not important. Consequently, the factory
setting for the under tolerance, Ltol (DS600P and DS600PC only) is 100% which disables
under detection. When under detection is activated by setting the Ltol parameter to a value less
than 100, it may be necessary to set the “under delay”, Udly, to a value greater than zero.
The under delay is a “delay-on” time for reporting an under condition. The units of the delay
setting are hundredths of a second (10 milliseconds). The delay-on to under allows material to
be brought into position in front of the probe without reporting an under condition while the part
and probe align. The delay range is .01 seconds to 2 seconds.
3.8 Gauging Response
After calibration, the DS600 responds to the probe signal by appropriately indicating the gauging
state and activating the control outputs. The response is dependent upon the gauging mode, the
position of switches 2 and 3 and the strength of the signal from the probe.
Table 5 shows the response of the DS600 ACCEPT and REJECT LEDs and ACCEPT and
REJECT outputs to various gauge signal levels and switch 2 settings for single/double sensing.
Table 6 shows the response of the DS600P and DS600PC ACCEPT and REJECT LEDs and
ACCEPT, REJECT, and AUX control outputs to various gauge signal levels and switch 2
settings for single/double sensing.
The single/double sensing mode is intended for metal forming applications where it is imperative
that only a single thickness of the sensed material is allowed to pass.
It is worth noting that the REJECT output operates with fail-safe levels. The signal is ON for no
reject and off for reject. Thus, if the controller loses power, a reject is reported by default.
For firmware Version 1.11 and later, the REJECT output is also OFF during initialization after
power-up, whenever nEEd Cal is displayed, and during the calibration process. The ACCEPT
output is OFF during these same intervals.
OFF
ON
ON
4
ON
OFF
OFF
5
ON
OFF
ON
6
ON
ON
OFF
7
ON
ON
ON
8

DS600 Non-Ferrous Double Sheet Detector
This document is confidential and proprietary. No part of this document may be disclosed in any manner
to a third party without the prior written consent of Prime Controls, Inc.
202177 16 Revision M
Table 5 – Model DS600 Single/Double Sensing
Gauge Signal
SW 2
ACCEPT
LED
ACCEPT
Output
REJECT
LED
REJECT
Output
< No-metal Threshold
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
RED
OFF
>= No-metal Threshold
OFF
GREEN
ON
OFF
ON
<= Single/Double Threshold
ON
GREEN
ON
OFF
ON
> Single/Double Threshold
OFF
OFF
OFF
RED
OFF
ON
OFF
OFF
RED
OFF
Symbols:
< is less than, > is greater than, <= is less than or equal to, >= is greater than or equal to.
Table 6 – Models DS600P and DS600PC Single/Double Sensing
Gauge Signal
SW 2
ACCEPT
LED
ACCEPT
Output
REJECT
LED
REJECT
Output
AUX
Output*
< No-metal Threshold
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
RED
OFF
ON
>= No-metal Threshold
OFF
OFF
OFF
RED
OFF
OFF
<= Under Threshold
ON
OFF
OFF
RED
OFF
OFF
>= Under Threshold
OFF
GREEN
ON
OFF
ON
ON
<= Single/Double Thresh
ON
GREEN
ON
OFF
ON
ON
> Single/Double Thresh
OFF
OFF
OFF
RED
OFF
ON
ON
OFF
OFF
RED
OFF
ON
* Only if switch 3 ON.
The part present sensing mode may be used to insure that a second component is present on
an assembly. A typical application would be to insure that a captive nut is in place on an
assembly. The logic of part present sensing is reversed as compared to single/double sensing.
Here the stronger signal, indicating more material, is the accepted condition while in
single/double sensing the stronger signal indicates the unwanted condition of too much material.
Table 7 shows the response of all DS600 model ACCEPT and REJECT LEDs and ACCEPT,
REJECT, and AUX control outputs to various gauge signal levels and switch 2 settings for part
present sensing.