Roland Double Sheet Detector R1000 Series User manual

DOUBLE SHEET CONTROL R1000 SERIES I20
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Double Sheet Detector I20
R1000 series
Inductive principles –
microcontroller based
Double sided non contact double sheet control of ferrous and non ferrous material
4 exchangeable linearized pairs of sensors for double sheet control of 0.15 – 10 mm
(.004 - .255 inch) sheet thickness
4-channel version allows connection of up to four pairs of sensors
►Suitable for magnetic feeder systems
►Programmable for 255 different sheet thicknesses and materials
►Calibration by Teach-In procedure
►Digital display of sheet thickness and operational parameters
►Monitoring of over-gauge and under-gauge limit
►Monitoring of operating voltage sensor gap
►Galvanically isolated 10-bit input interface and 5-bit output interface

Copyright
©
2015 ROLAND ELECTRONIC GmbH
Otto-Maurer-Str. 17
DE 75210 Keltern
All rights on this document are at Roland Electronic GmbH.
Reproduction (also partly), electronical coverage, translation, transmission to third parties,
only with our prior permission.
Subject to change without further notice.
===== Ende der Stückliste == ===

Manual
Double Sheet Detector R1000 Series I20
B0069991 / Rev. 1.7 Table of contents
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Declaration of conformity according to EC directives .....................................................................................5
1Safety advices ........................................................................................................................................6
1.1Safety instructions and warnings for user ..........................................................................................6
1.2Declaration of icons ............................................................................................................................7
1.3Intended use.......................................................................................................................................7
2Technical data ........................................................................................................................................9
2.1Technical data control unit I20............................................................................................................9
2.2Versions of the control unit I20 .........................................................................................................10
2.3Sensors.............................................................................................................................................10
2.4Dimensions of the sensors ...............................................................................................................14
2.5Sensor cables ...................................................................................................................................15
2.6Scope of delivery (accessories)........................................................................................................16
3System description..............................................................................................................................17
3.1Measurement principle .....................................................................................................................17
3.2System type ......................................................................................................................................17
3.3General hints for process reliability ..................................................................................................19
3.4Control unit .......................................................................................................................................20
3.5Parameters of the control unit ..........................................................................................................20
3.6Application examples........................................................................................................................27
3.7Tailor Welded Blanks........................................................................................................................33
3.8Design information regarding transporting velocity ..........................................................................33
3.9Secondary magnetic flux ..................................................................................................................35
4Mounting...............................................................................................................................................37
4.1General mounting instructions..........................................................................................................37
4.2Dimensions of the system ................................................................................................................38
4.3Mounting of sensors .........................................................................................................................40
4.4Sensor mounting in magnetic conveyors .........................................................................................44
5Electrical installation ...........................................................................................................................47
5.1General instructions..........................................................................................................................47
5.2Configuration of connectors..............................................................................................................47
5.3Connecting diagram - examples.......................................................................................................50
6Communication with the PLC .............................................................................................................55
6.1PLC inputs ........................................................................................................................................55
6.2PLC output signals ...........................................................................................................................55
6.3Timing diagrams ...............................................................................................................................57
6.4Internal control (Demo mode)...........................................................................................................68
7Start-up..................................................................................................................................................69
7.1Initially applying power to the system...............................................................................................69
7.2Start screen ......................................................................................................................................69
7.3Operation ..........................................................................................................................................70
7.4Configuration menu ..........................................................................................................................71
7.5General information regarding the configuration ..............................................................................76
7.6Changing, setting-up or checking the configuration .........................................................................76

Manual
Double Sheet Detector R1000 Series I20
Table of contents B0069991 / Rev. 1.7
4 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
7.7Program parameters ........................................................................................................................ 78
7.8Adjustment parameters.................................................................................................................... 87
7.9System parameters.......................................................................................................................... 89
7.10Data backup..................................................................................................................................... 96
7.11Firmware update .............................................................................................................................. 96
8Operation...............................................................................................................................................99
8.1Abbreviated operating instructions .................................................................................................. 99
8.2Entering a measurement program ................................................................................................. 100
8.3Zero adjust (after sensor exchange).............................................................................................. 101
8.4Teach-In......................................................................................................................................... 101
9Fault messages, causes and remedies........................................................................................... 103
9.1Faults concerning memory ............................................................................................................ 104
9.2Faults concerning USB data transmission (virtual RS232)............................................................ 105
9.3Faults concerning system operation .............................................................................................. 105
9.4Faults concerning keyboard........................................................................................................... 105
9.5Faults concerning parallel interface ............................................................................................... 105
9.6Faults concerning sensor test........................................................................................................ 106
9.7Faults concerning Teach-In / Zero adjust ...................................................................................... 106
9.8Faults concerning sensors / sensor cables.................................................................................... 106
9.9Faults concerning Hardware.......................................................................................................... 107
9.10Faults concerning supply voltage .................................................................................................. 107
9.11Other faults .................................................................................................................................... 107
10Maintenance....................................................................................................................................... 109
10.1Replacement of sensors ................................................................................................................ 109
10.2Exchange of control unit ................................................................................................................ 109
10.3Replacement of fuses .................................................................................................................... 110
10.4Data backup via USB interface...................................................................................................... 110
10.5Firmware update via USB interface ............................................................................................... 111
10.6Spare parts .................................................................................................................................... 111
11Technical records.............................................................................................................................. 113
11.1Exchange of equipment ................................................................................................................. 113
12Order data .......................................................................................................................................... 114
12.1Versions of control unit I20 ............................................................................................................ 115
12.2Sensors.......................................................................................................................................... 115
12.3Cables............................................................................................................................................ 115
12.4Cable plugs and cable sockets ...................................................................................................... 116
12.5Other accessories (within scope of delivery) ................................................................................. 116
13Appendix ............................................................................................................................................ 117
13.1System configuration form ............................................................................................................. 117

Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7 Safety advices
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Declaration of conformity according to EC directives
Manufacturer: Roland Electronic GmbH
Otto-Maurer-Str. 17
DE 75210 Keltern
Product name: I20
Product type: Double Sheet Detector-series I20
Roland Electronic GmbH declares that the product listed above complies with the requirements of
the EMC directives listed below.
Applied Directives:
2006/95/EG Low Voltage Directive
EN61010-1: 2010
2004/108/EG: EMC Directive
EN61000-6-2: 2005-08 EN61000-6-4: 2007-01
Date of mark’s apposition: 12.03.2015
Keltern, 12.03.2015 Managing Director
Place, Date Signature Function of the signer
The declaration confirms the compliance with the cited directives. However, it is not any implied warranty of fitness for a
particular purpose especially as it may relate to product liability.
The safety instructions and warnings must be observed.
ISO 9001 : 2008
Reg.-no. 5152 QM08

Manual
Double Sheet Detector-series I20
Safety advices B0069991 / Rev. 1.7
6 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Blank page
1 Safety advices
1.1 Safety instructions and warnings for user
This handbook contains all information required for the correct operation of the Roland equipment.
It has been written for technically qualified personnel. Unauthorized tampering with the unit,
especially ignoring the warnings in this handbook, can cause malfunction and damage to the unit.

Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7 Safety advices
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Only authorized personnel should be allowed to make changes to the unit and perform cable
connections especially the power supply.
Should it be necessary, e.g. in case of service or repair, to make measurements within the unit,
then all customary accidents prevention procedures should be observed. Only professional
electrical tools should be used.
Note The factory pre-settings – especially the upper / lower limit values – have
been chosen such that an optimal machine protection is ensured.
Diverging settings can impair the machine protection.
Safety advice for persons with cardiac pacemakers!
Persons with cardiac pacemakers are to stay away from the sensors!
The strong magnetic / electromagnetic fields of the sensors can cause malfunction
of cardiac pacemakers and other such apparatus!
1.2 Declaration of icons
Warning - general dangers!
Reference to imminent hazards, which can result in severe bodily harm or death.
Warning - dangers by high voltage!
Reference to imminent hazards due to electricity, which can result in severe bodily
harm or death.
Attention - Damage of construction units!
Reference to a potential imminent situation, which can result in damage to the
product or environs.
Note
Useful reference to an application or deepening information.
1.3 Intended use
Flexible Manufacturing Systems in the sheet processing industry require reliable Double Sheet
Control systems in order to protect presses and other sheet processing machines against damage
caused by feeding multiple sheets.
The Double Sheet Detector R1000 I20 was specifically developed for this technical environment.
Depending on the application (type of material, thickness, sensor gap) the I20 can be used with up
to four pairs of sensors. The reliable function of the Double Sheet Detector depends therefore most
importantly on the selection of the correct sensors and the mounting of the sensors.

Manual
Double Sheet Detector-series I20
Technical data B0069991 / Rev. 1.7
8 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Blank page

Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7 Technical data
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
2 Technical data
2.1 Technical data control unit I20
Technical data control unit I20
Operating voltage: 24 VDC, +6 V / -4 V
Power consumption: 15 W
Switch on current: 10 A for 1 ms
External fuse: 1 A medium time lag
Ambient temperature: 0 - 50 °C (30 - 122° F)
Wall mount enclosure I20-2-O-S I20-4-O-S
Protection category: IP65
Dimensions, approx.. (W x H x D) mm 225 x 206 x 112 225 x 206 x 112
Dimensions, approx.. (W x H x D) inch 8.9 x 8.1 x 4.4 8.9 x 8.1 x 4.4
Weight, approx 4.0 kg (8.81 lbs)
Valid from SN-No. 104358 delivery date 09/03/2009
Front panel enclosure I20-2-O-S-FP I20-4-O-S-FP
Protection category: IP40 (inside), IP65 (front cover)
Dimensions, approx.. (W x H x D) mm 240 x 240 x 120 240 x 240 x 170
Dimensions, approx.. (W x H x D) inch 9.45 x 9.45 x 4.7 9.45 x 9.45 x 6.7
Weight, approx 2.2 kg (4.85 lbs)
Additional characteristics:
255 parameter sets memory
Programming via front panel keys
10 galvanically isolated
optocoupler inputs 24 VDC with
common external supply
Specification:
- min. switching voltage HIGH: 13 VDC
- max. switching voltage HIGH: 30 VDC
- min. switching voltage LOW: 0 VDC
- max. switching voltage LOW: 8 VDC
5 potential free outputs
with positive external supply
Specification:
- switching output: unwired Emitter and Collector
- max. switching voltage: 30 VDC
- max. switching current: 500 mA
Virtual RS232 interface (via USB) for data backup
USB interface for Firmware update
Attention In order to protect the outputs from damage by inductive spikes, the
outputs need to be protected by amply dimensioned flyback diodes.

Manual
Double Sheet Detector-series I20
Technical data B0069991 / Rev. 1.7
10 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
2.2 Versions of the control unit I20
The control unit article key ist coded as follows:
Control unit I20 with optocoupler interface
I20-2-O-S-FP
A Type of unit I20
B Number of sensors 2
4
up to 2 sensors
up to 4 sensors
C Outputs O Optocouplers
D Connection S pluggable
A B C D E E Enclosure FP Front panel mounting
Based on the product key shown above, the following versions are available:
I20-2-O-S
Data backup
via serial USB
interface
Control unit for wall mounting, connection of up to 2 sensors,
IN/OUT interface
I20-4-O-S Control unit for wall mounting, connection of up to 4 sensors,
IN/OUT interface
I20-2-O-S-FP Control unit for front panel mounting, connection of up to 2 sensors,
IN/OUT interface
I20-4-O-S-FP Control unit for front panel mounting, connection of up to 4 sensors,
IN/OUT interface
2.3 Sensors
The sensor description has the following code:
IS20-30GS
A B C D E
A: Inductive sensor
B: S = transmitter, E = receiver
C: Diameter of sensor head
D: Thread
E: Quick disconnect
2.3.1 Sensor pair IS20-30GS / IE20-30GS
Technical data
Application: Double sheet detection
Sheet thickness:
0.05 – 4 mm for steel
0.05 – 10 mm for Aluminum (LW 20 – 30 MS/m):
0.2 – 10 mm for austenitic Stainless steel
at nom. sensor distance (min. / max.)
20 (10 – 40) mm
20 (10 – 40) mm
20 (10 – 40) mm
Sensor distance: see sensor diagrams
Measurement principle: Eddy current
Protection class: IP54
Weight: ca. 0.25 kg (0.55 lbs)
Material of enclosure: Stainless steel / Brass, Nickel plated
Sensor cable: Quick disconnect

Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7 Technical data
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
2.3.2 Sensor pair IS42-30GS / IE42-30GS*
Technical data
Application: Double sheet detection
Sheet thickness:
0.15 – 8 mm for steel
0.1 – 10 mm for Aluminum (LW 20 – 30 MS/m):
0.4 – 10 mm for austenitic Stainless steel
at nom. sensor distance (min. / max.)
40 (20 – 80) mm
40 (20 – 80) mm
40 (20 – 80) mm
Sensor distance: see sensor diagrams
Measurement principle: Eddy current
Protection class: IP54
Weight: ca. 0.45 kg (1 lbs)
Material of enclosure: Stainless steel / Brass, Nickel plated
Sensor cable: Quick disconnect
* Transmitter ISQ42. and receiver IE42-30.. may be also used as a sensor pair. Please refer to
chapter 4.3.1 for an example.
2.3.3 Sensor pair ISQ42S / IEQ42S*
Sensor pair ISQ42FS / IEQ42FS*
Technical data
Application: Double sheet detection
Sheet thickness:
0.15 – 8 mm for steel
0.1 – 10 mm for Aluminum (LW 20 – 30 MS/m):
0.4 – 10 mm for austenitic Stainless steel
at nom. sensor distance (min. / max.)
40 (20 – 80) mm
40 (20 – 80) mm
40 (20 – 80) mm
Sensor distance: see sensor diagrams
Measurement principle: Eddy current
Protection class: IP54
Weight: ca. 0.50 kg (1.1 lbs)
Material of enclosure: Plastic
Sensor cable: ISQ / IEQ42S: Quick disconnect
ISQ / IEQ42FS: 0,2 m, cable firmly connected, with cable plug
* Transmitter ISQ42S and receiver IE42-30S, respectively transmitter IS42-30S and receiver
IEQ42S may be also used as a sensor pair. Please refer to chapter 4.3.1 for an example.
2.3.4 Sensor pair ISQ160S / IEQ160S
Technical data
Application: Part inspection, Material inspection, Hardness inspection
Sheet thickness: Depending on the application
Sensor distance: 20 – 80 mm (depending on the application)
Measurement principle: Eddy current
Protection class: IP54
Weight: ca. 0.50 kg (1.1 lbs)
Material of enclosure: Plastic
Sensor cable: Quick disconnect
Note The stated measurement ranges are only valid for systems in „Standard“
setting. For details refer to chapter 3.2.

Manual
Double Sheet Detector-series I20
Technical data B0069991 / Rev. 1.7
12 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
2.3.5 Sensor diagrams
Sensor diagrams are available for determining the admissible measuring range depending on the
gap between transmitter and receiver (Ax) and the material. Ax is specified as follows:
Fig. 1: Transmitter-receiver gap Ax
The marked areas represent the working ranges of the sensors. For all combinations of sheet
thickness and sensor distance Ax within the range a double sheet condition will be reliably
detected, if the switching thresholds are set “tight”.
The working ranges of the sensors depend very much on the material properties, they can deviate
from the sensor diagrams shown below.
Note The stated measurement ranges are only valid for units of type
„Standard“. For details refer to chapter 3.2.
Ax diagrams for sensors IS / IE20-30GS
Fig. 2: Sensor diagrams for sensors IS / IE20-30GS
A
xBlech
Shee
t
30
20
10
01
0,05 234
A
x
/
mm
STEEL
Ax (2 n)
Ax (n)
A
x (½ n)
40
30
20
10
01
0,05 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ax / mm
ALUMINUM
Ax (2 n)
Ax (n)
A
x (½ n)
40
30
20
10
01
0,2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ax / mm
Sheet thickness / mm
STAINLESS STEEL(Austenitic)
Ax (2 n)
Ax (n)
A
x (½ n)
Sheet thickness / mm
Sheet thickness / mm
Ax(n) = nominal sensor gap

Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7 Technical data
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Note The stated measurement ranges are only valid for systems in „Standard“
setting. For details refer to chapter 3.2.
Ax diagrams for sensors IS / IE42-30GS and ISQ / IEQ42S
Fig. 3: Sensor diagrams for sensors IS / IE42-30GS / ISQ / IEQ42S
Ax diagrams for sensors ISQ / IEQ160S
The sensors are specifically designed for Monitoring Parts for Hardened / Tempered Properties
and Materials Mix up. The sensor gap can range from 20 to 80 mm depending on the geometry of
the parts to be tested.
Note If more than 1 pair of sensors is connected to the system, the sensor
gaps may not deviate from each other more than ±10%. Otherwise the
zero adjustment can be faulty.
Example: S1: 40 mm S2: 42 mm S3: 39 mm S4: 43 mm
All values are within ±10%.
80
60
40
20
0
20,15 46 8
Ax / mm
STEEL
135 7
Ax (2 n)
Ax (n)
A
x (½ n
)
80
60
40
20
0
1
0,1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ax / mm
ALUMINUM
70
50
30
Ax (2 n)
Ax (n)
A
x (½ n
)
80
60
40
20
0
1
0,4 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ax / mm
30
50
70
Ax (2 n)
Ax (n)
A
x (½ n
)
Sheet thickness / m
m
Sheet thickness / m
m
Sheet thickness / mm
Ax(n) = nominal sensor gap
STAI N L ESS ST EEL (Au st e n itic)

Manual
Double Sheet Detector-series I20
Technical data B0069991 / Rev. 1.7
14 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
2.4 Dimensions of the sensors

Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7 Technical data
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Fig. 4: Dimensions of IS/IE sensors bis SE75.wmf
2.5 Sensor cables
Cable marking:
The cables have quick disconnects at both ends. The plug at the control unit side is always
straight.
SCI20S-GG with straight cable socket at the sensor
SCI20S-GW with right angle cable socket at the sensor
SCI20S-GG-TE extension cable for sensor cable (also use as quick disconnect)
Applicable to all cables: Bending radius: 50 mm at fixed installation
100 mm at flexible installation
Cable diameter: 7.1 mm
Suitable for drag chains, oil-proof, PUR jacket
Superflex Tronic(C)PUR TP 4 x 2 x 0.25 mm²
Note The sensor cable is an active component of the sensor technology.
The technical data of the sensors is valid only if the cable specification is
met. A shielded cable must be used.
The cable length can be to up to 50 m. Following the rule "the shorter the
better" generally leads to better measuring results.

Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
16 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Cable extension SCI20S-GG-TE
The cable extension SCI20S-GG-TE is inserted between the control unit and the existing regular
sensor cable SCI20S-GG, SCI20S-GW.
Note: This cable must be used if the sensors ISQ/IEQ42FS (with firmly
connected cable) are taken.
2.5.1 Allocation of sensor cables SCI20S-GG, SCI20S-GW and SCI20S-GG-TE
Fig. 5: Allocation of sensor cables SCI20S-GG, SCI20S-GW and SCI20S-GG-TE
2.6 Scope of delivery (accessories)
Within the scope of delivery there are accessorial parts, which are separately packaged and put
into the shipment box.
The volume of accessories depends on
the version of the control unit.
It is shown in Chapter 5.2
“Configuration of connectors“.
Fig. 6: Accessories, packaged

Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7 System description
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
3 System description
Flexible production systems in the sheet processing industry require automated, reliable double
sheet detection in order to protect presses and other processing machinery from damage by
multiple sheets. The I20 was specifically developed for this technical environment. The I20 is based
on the product platform R1000 and consists in the standard version of three components:
• a control unit
• one pair of sensors (transmitter and receiver)
• one pair of sensor cables
3.1 Measurement principle
The function of the sensor system is based on the measurement of eddy currents. The sensor
system consists of a transmitter and a receiver.
The transmitter generates an electromagnetic field, which generates eddy currents in the target.
The eddy current loss in the sheet dampens the electromagnetic field. These losses are measured
in the receiver and are a measure of the sheet thickness (see also section ”Sensor diagrams“).
3.2 System type
With the system parameter “System type“ the function of the I20 can be fundamentally changed.
Possible choices are:
a) Standard
Here mm or inch can be selected as dimension.
The nominal sheet thickness as well as the material must be entered.
For NF (nonferrous) material the electrical conductivity must be entered,
or the conductivity must be determined at sheet standstill. Only then a
dynamic Teach-In can be performed.
The materials which can be measured depend on the restrictions of the
sensor pair used.
b) FE + AL 0.5 - 3 mm
c) FE + AL 0.1 - 0,8 mm
d) FE + Austenite 0.1 - 1 mm
f) FE + Austenite 0.5 - 3 mm
Restricted measurement range !
Here only % can be selected as dimension.
The nominal sheet thickness does not need to (/cannot) be entered.
Only FE (ferrous) and NF (nonferrous) material are available for
selection.
A dynamic Teach-In can be directly performed.
Depending on the selection (b - f) only those materials and thicknesses
can be measured! (restricted measurement range!)
g) Frequency
Monitoring Parts for Hardened / Tempered Properties and Materials Mix
up. The input of nominal dimensions is not necessary. The measurement
frequency is adjusted according to the task under consideration (review
the following explanations)
h) Damping mode
Within the system parameter „System type - Standard“ there will be no
error-free dynamic Teach-In execution in a sophisticated constellation of
work environment. The error message 151 "Sheet too thick" is reported.
This problem occurs especially when using magnetic conveyors. For this
case you must choose the system type “Damping mode“.
With the selections b) – f) the following applications are conceivable:
• Only 2 programs are used, one program for ferrous and the other one for nonferrous
material. With each change of material the program for the corresponding material is
switched and the first sheet is used for Teach-In.
• All programs are used. The Teach-In can be performed with running sheet, without stating
nominal thickness and conductivity.
The selections b) - f) are intended as substitution for the mode “Dimension %“ known from the
I10K.

Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
18 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
3.2.1 Explanation for System type “Frequency”
This adjustment of the I20 is used for applications to identify non-hardened or defective parts. The
parts are passed through a sensor C-frame in which they are exposed to an eddy current field.
Non-hardened or defective parts have a different field attenuation from good parts and can
therefore be separated.
Roland Electronic supports the use with no charge application tests in order to ensure the feasibility
of the project and obtain the optimum control unit adjustments.
Differences of the Adjustments of the I20 in Comparison to the Standard Use.
Teach-In
• Instead of the single sheet (1-sheet) part A is used for a teach in of 100%
• Instead of two sheets (2 sheets) part B is used for a teach in of 200%
Sensors
• The pair of sensors ISQ160S/IEQS160S is primarily used for the system type "Frequency".
• Depending of the results of the application tests, the transmitter and the receiver are
mounted in line either vertically (0°) or horizontally (90°).
Illustration with 0° and with 90°
Fig. 7: Illustration with 0° and 90°
Sensor Gap and Measuring Position
• The sensor gap must remain constant during the operating mode "Frequency".
The sensor bracket must be correspondingly designed for this purpose.
• The measurement position of the part to be tested must be identical during Teach-In and
measurement.
• For this application glass turntables are very well suited, magnetic transportation systems are
not recommended.

Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7 System description
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Fig. 8: Glass turntable
Operation
• Instead of the nominal thickness the test frequency is selected for the adjustment of the
program parameters. The type of material adjustment is not necessary. The optimum test
frequency is determined at no charge in the application lab.
• The Teach in of 1 sheet and 2 sheet is substituted by the Teach-In of part A and part B
respectively. Preferably a good part is being used being used for the Teach-In.
3.3 General hints for process reliability
The process security of the system is influenced by the following factors:
• the stability of the measuring values
• the setting of under-gauge threshold and over-gauge threshold
• the evaluation of the status signals
Stable measuring conditions will result in stable measuring results. Varying measuring results are
undesirable, because in such cases the user is inclined to decrease the under-gauge threshold and
to increase the over-gauge threshold. On doing so, the user puts up with the drastically increasing
risk of not detecting a double sheet.
The following external factors decisively influence the stability of measuring results and need to be
considered for operation of a double sheet detector:
• the magnetic characteristics of the material
• the tolerance in material thickness
• the geometric conditions at the place of measurement and at the sheet
• the pre-magnetization of FE material in case of magnetic transport systems.
• the smooth run of the material, with low vibrations

Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
20 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
From this, some simple rules can be derived, to enable a high process security when abided by:
• Every different sheet (Thickness, material and contour) is measured with separate
measuring program. For exceptions see chapter 3.6.
• The Teach-In has to be done with the same sheets (Thickness, material and contour)
used when measuring.
• Adjust the switching thresholds as tight as possible!
• Keep the sensor gap constant!
• Ensure for sufficient covering of the measuring target!
• Keep the pre-magnetization of FE material as low as possible (suitable mounting of the
transport magnets)!
• Pass the material guided through the sensor!
Furthermore it is necessary that the machine controls checks all status signals of the I20, also the
0-sheet signal. While measuring, only the 1-sheet signal may occur. If 0-sheet or 2-sheet occurs,
the measured sheet may not be transported on. In such cases, the sheet will usually be removed.
• The machine controls needs to evaluate all status signals !
Checking-up through the 0-sheet signal is to assure that a sheet really is between the sensors
during measuring. If 0-sheet occurs while measuring, the measurement is not correct. For example,
a defective sensor holder might change the sensor gap. Monitoring the sheet thickness would then
only be performed apparently.
In case of double sheet severe consequences could then result.
3.4 Control unit
The I20 is based on the product platform R1000.
Major features of the control unit:
• Programmable for 255 different sheet thicknesses / types of sheets
• Calibration by a Teach-In procedure
• Digital display of sheet thickness and operating parameters
• Monitoring of over gauge and under gauge limits
• Monitoring of operating voltage and sensor gap
• Opto coupler for direct I/O control via the PLC for fast measurement operations
• Software firmware update
• Data backup via USB interface
3.5 Parameters of the control unit
The I20 provides for extensive configuration. So, different customer requirements can be served.
Configuration is performed by setting system parameters and program parameters.
System parameters are set only once during commissioning, and will then remain unchanged.
Program parameters contain items which are material and job depending, and enable individual
adaptation to the measuring task.