Prime DS100 User manual

OPERATING INSTRUCTIONS
Model DS100 DOUBLE SHEET DETECTOR
DESCRIPTION
The Model DS100 Double Metal Sheet Detector comprises a control module in a sheet metal
housing with a single probe to form a system that detects the thickness of metals passing the face
of the probe. The detector system may be used on automatic sheet feeders where double or
overlapped sheet material may jam or damage the receiving machine. A double feed produces an
output to stop the machine or signal the operator. March 09, 1998
NO DOUBLE DOUBLE
CALIBRATE
Model DS100
Double Metal
Sheet Detector
PRIME
CONTROLS, INC.
AC AC
RELAY
POWER DOUBLE

RESET
COM
NOTHING
WHITE
RED
CAL
BLACK
SHLD
PROBE
CONTROL
SET JUMPERS
(120V OR 240V)

2
Control Module
The control module allows fast and easy setup and for diagnosis of system errors or problems.
Calibration is achieved through the simple press of a push-button switch. Faults are reported
through different flash patterns on the green and yellow "no double" and "double" indicators.
When the unit first powers up, the two indicators flash alternately as the unit determines which
model of probe is attached. If the probe is not recognized, the flash pattern changes with the
DOUBLE indicator on solid and the NO DOUBLE indicator flashing. When probe assessment
has completed successfully, the indicators stop flashing
Other features of the control module include:
•95 to 130 or 200 to 250 volt operation selected through internal jumpers.
•Removable terminal blocks for quick change out of the control module.
•Form C relay output providing normally open or normally closed contacts.
•LED indicators report the gage states of NO DOUBLE and DOUBLE.
•Automatic setup of system gain and operating parameters.
•Simple push-button calibration.
•Non-volatile memory that retains all calibration parameters even when power is removed.
•Latching relay output that is cleared by asserting the RESET input.
•Probe fault detection and reporting via the two front panel indicators.
•External Calibrate terminals for convenient placement of the calibrate switch
•Metal present output to verify the sheet has fed properly
Probes
The DS100 operates with a several different Prime magnetic probes including Models PM4,
PM10, and PM15. All probes are potted and completely sealed. The probes do not respond to
small amounts of fine metal filings, oil or dirt.
Probe Model Min thickness Max thickness Probe Diameter
PM4 .04 mm (.0015”) .40 mm (.015”) 18 mm (0.70”)
PM10 .10 mm (.004”) 1.0 mm (.040”) 30 mm (1.18”)
PM15 .15 mm (.006”) 1.5 mm (.060”) 36 mm (1.42”)

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INSTALLATION
Installation of the individual components of the Double Metal Sheet Detector system is covered in
the following paragraphs:
DS100 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 6.5 inches (165 mm) by 6.25 inches
(159 mm) with mounting slot locations on a rectangle 5.875 inches (149 mm) in the horizontal
and 4.0 inches (102 mm) in the vertical (see drawing at end of this document). Insure that the
mounting screws make good electrical contact between the module housing and a well grounded
control enclosure back panel.
Avoid mounting locations with excessive heat and vibration.
Probes
The probe must be mounted so that the sheet is in contact with the probe face as it passes. The
face of the probe is made of magnetic material and will last for many years of operation.
The Model DS100 Double Sheet Detector can be made to operates with no contact between the
sheet material and the probe if the gap is kept very small and is held constant. A constant gap is
very important since a small change in gap causes significant change in the sensor signal. If the
system is to be operated with a gap between the probe and the sheet material, the unit must be
calibrated after the gap is established. If the gap is too large, the unit may fail to calibrate.
Electrical Wiring
All wiring for the DS100 connects to removable terminal blocks at the bottom of the control
enclosure as described in the following paragraphs.
1. Connect l00 to l30 VAC (50-6O Hz. @15watts) to the terminals labeled AC on the left of
terminal block. Connect earth ground to the leftmost terminal.
2. For 200 to 260 volt operation remove the DS100 cover and remove suitcase jumpers Aand
Cimmediately in front of the gray transformer block. Place one of the suitcase jumpers in
position B. Discard the second jumper. Replace the cover. The factory setting for these
jumpers is for 100 to 130 volt operation. Do not power the Model DS100 with 200 to 260
VAC until jumpers have been changed.
3. Connections to the control circuit of the machine are made through the form C output relay.
This relay is powered in the NO DOUBLE condition. If power is lost to the control the relay
is not energized and the DOUBLE contact is closed.

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4. Shielded cable from the probe to the board should be run in conduit. The probe is connected
to terminals on the rightmost terminal block labeled Red, White, Black & Shield. Connect
the shield leads (drain wires) from the probe cables to the terminals labeled SHLD. If a splice
is made between the control and probe leave the probe unshielded no more than 20 to 30
mm.
5. The output relay may be operated in a "follower" mode or "memory" mode depending upon
the wiring of the RESET input. The mode connections and definitions are described below.
a) To operate the output in the "follower" mode, jumper RESET and COM. together on the
terminal block. When a DOUBLE condition occurs, the relay drops out and the DOUBLE
indicator comes on. When the double metal condition is removed, the relay returns to the
normally energized condition, the amber DOUBLE indicator goes out and the green NO
DOUBLE indicator turns on. Automatic reset is normally selected to control the operation
when the fault condition is automatically removed or the DS100 is wired into the stop circuit
of a machine with a manual restart circuit.
b) To operate the output in a "latch" mode, wire the RESET and its associated COM terminal to
the normally open contact of a switch, relay, or controller output. In this mode, when a fault
condition occurs, the relay drops out and the DOUBLE indicator comes on. After the fault
condition is corrected, the RESET contact must be momentarily activated to bring the relay
back to the NO DOUBLE state.
INPUTS AND CONTROLS
The primary control input to the DS100 is the calibration push-button switch on the front panel.
Use of this switch is described below under CALIBRATION.
The DS100 has two logic inputs labeled CAL and RESET. The CAL input parallels the function
of the calibrate push-button on the front panel allowing the calibration function to be performed
through a remotely located switch wired to this input. The RESET input controls the latching of
the relays as described in item 5 of the Electrical Wiring section above.
The two logic inputs have associated with them two jumper plugs located under the front cover
and immediately behind its associated terminal. The function of these jumpers is described
below under CONFIGURATION SWITCHES AND JUMPERS.
Both the CAL and RESET inputs are ON when low (zero volts) independent of the jumper
settings.
A two position DIP switch between the two main connectors, is visible from the connector edge
of the unit. These switches control the selection of the calibration mode and the system response
time as described below under CONFIGURATION SWITCHES AND JUMPERS.

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OUTPUTS
The DS100 outputs include a form C relay for reporting OVER conditions and a dc logic output
for reporting no material in front of the probe.
The logic output is labeled the NOTHING output since it provides an indication that nothing is
present in front of the probe. The intent of this output is to signal that a sheet did not feed. This
output provides a dc sourcing signal that switches between zero volts and 22 volts, delivering up
to 100 mA.
The NOTHING output is ON (sourcing at 22 volts) when material is present in front of the probe.
INDICATORS
The function of the indicators and controls on the DS100 are described in the following
paragraphs:
1. The amber DOUBLE indicator is ON whenever the received signal is closer to the calibrated
value for double thickness than to the calibrated value for single thickness.
2. The green NO DOUBLE indicator is ON whenever the received signal is closer to the
calibrated single thickness value than to the calibrated double thickness value.
Through various flashing patterns, these indicators also provide information regarding system
mode (calibrate vs operate), firmware version number, and error conditions. Reading firmware
version is described later in this document. All other flash patterns can be interpreted as follows:
Alternate flashing of amber and green indicates busy such as during initialization after power-up.
Simultaneous flashing of amber and green indicates failed calibration. The reasons are various
such as calibration sample too thick, sample too thin, too little difference between double and
single, or too much air gap between metal and probe.
Green flashing, amber off - awaiting single sample for calibration.
Amber flashing, green off - awaiting push-button press for calibration on double.
Green flashing, amber on - probe error. Probe may not be connected, probe wire broken, or
probe may be defective.

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CONFIGURATION SWITCHES AND JUMPERS
A two position switch is located on the main control circuit board in the opening between the
two connectors. In units with version 1.3 or later firmware, the right switch determines the
response time of the system as detailed below. The right switch is not used on units with version
1.2 or earlier firmware. The switch on the left selects one or two “hit” calibration as described
below in the CALIBRATION section of this document.
Left Switch: UP selects calibrate on single.
DOWN selects calibrate on single and double
Right Switch: UP selects standard (12 millisecond) response time.
Left Switch DOWN selects high speed (2 millisecond) response time.
NOTE: These switches are read only at power up. If a switch setting is
changed, be sure to power the unit down and back up again.
Each of the logic inputs (CAL and RESET) 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 (NPN) or sourcing (PNP) 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 (factory setting), the input is set up
for a sinking driver, or dry contact between the input and COM. Both inputs are active low.
CALIBRATION
The detector may be calibrated via the push-button switch on the front cover or remotely through
a switch connected between the CAL and COM terminals of the right terminal block.
The DS100 offers two modes of calibration: 1) calibrate on single nominal thickness, and 2)
calibrate on single and double thickness. Normally where double thickness discrimination is
required, the DS100 can be calibrated on a single thickness of the material to be monitored (one
press of the push button). If finer changes in thickness are to be discriminated, the DS100 may be
calibrated on two different thicknesses of the same material. The discrimination threshold is set
halfway between the two calibration points.
Calibration on Single Only
Calibration on single is selected when the left configuration switch is UP. See section on
CONFIGURATION SWITCHES AND JUMPERS above.
Place a single sheet of metal to be gauged against the probe face and press the CALIBRATE
push-button. During calibration on the single thickness, the green (NO DOUBLE) indicator
flashes and the amber (DOUBLE) indicator is off. If the calibration on the single is successful, the

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green indicator stops flashing and remains solidly on until the material thickness at the probe face
changes.
If the calibration is not successful, both indicators flash simultaneously. Make sure that the sheet
is solidly against the probe when calibrating or that the sheet thickness does not exceed the probe
specification. (See probe specifications on page 2). If everything seems to check out, re-try the
calibration. Alternatively try calibrating on single and double as described below. If difficulties
persist, call Prime Controls for technical assistance.
Calibration on Single and Double
Calibration on single AND double is selected when the left configuration switch is DOWN.
Place a single thickness of material against the probe face and press the CALIBRATE push-
button. During calibration on the single thickness, the green (NO DOUBLE) indicator flashes and
the amber (DOUBLE) indicator is off. When calibration on the single thickness is complete and
the unit is ready for the double thickness, the green indicator turns off and the amber indicator
flashes. Place a sample of thicker material or two samples of the single material against the probe
face and press the CALIBRATE push-button again. If calibration is successful, the amber
indicator stops flashing and remains solidly on and the green indicator is off.
If the calibration is not successful, both indicators flash simultaneously. The causes for
unsuccessful calibration can be many including too little difference in thickness between the thin
and thick material, poor probe contact, wrong probe model for the material, etc.
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 is displayed as one second flashes
of the NO DOUBLE LED for the integer digit followed by one second flashes of the DOUBLE
LED for the fractional digit. Count the number of flashes on each LED to determine the
revision number. Thus one flash of the NO DOUBLE LED followed by two flashes of the
DOUBLE LED indicates version 1.2 of the firmware.

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POWER REQUIREMENTS
95 to 130 volts, 50/60 Hz at 50 mA.
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: 20OW DC, 2,OOOVA 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

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TROUBLESHOOTING
Should trouble develop, proceed as follows:
1. Check AC input power to the control module
2. Check the fuse, accessible at the lower left side of the DS100 housing.
3. When powers is applied, if the green and amber indicators show a response to the metal
condition in front of the probe and the output relay does not switch, check that the reset
jumper is installed (if you want the relay to follow the sheet condition). The jumper is
installed between RESET and COM. on the terminal strip. If the unit is reset by an external
machine START button, check wiring across the Reset and COM terminals or the START
button contacts.
4. When power is applied, if the DOUBLE indicator is on solidly while the NO DOUBLE
indicator is flashing, check for a missing, disconnected, open, or shorted probe.
5. If both indicators flash in unison, the system is indicating an invalid calibration. The causes
can be many. Among them, an attempt to calibrate both double and single on the same
thickness material, a shorted receiver probe, probe gap too large, incorrect probes for the
material being gauged. If the problem cannot be resolved, call the factory for assistance.
For further information or service assistance, contact Prime Controls, Inc., 4551 Gateway
Circle, Dayton, Ohio 45440-1711. Phone: [phone], Fax: [phone]. Mention
model number and serial number.

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(6.50)
(5.875)
NO DOUBLE DOUBLE
CALIBRATE
Model DS100
Double Metal
Sheet Detector
PRIME
CONTROLS, INC.
AC AC
RELAY
POWER DOUBLE

(1.32)
(0.600)
15.2
33.5
165.1
149.2 7.9
(0.31)
(4.0)
101.6
(6.25)
158.8
(1.125)
28.6
RESET
COM
NOTHING
WHITE
RED
CAL
BLACK
SHLD
PROBE
CONTROL
SET JUMPERS
(120V OR 240V)

11
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. 2/8/99