Roland R100 Series User manual

Double Sheet Detector A100 R100 Series
Double Sheet Detector A100
R100 Series
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for single probe sensors
►Single probe sensors, permanent-magnetic
►Measurement of FE material 0.04 - 4 mm thickness
►Easy setup by key operation or via control input
►LCD display for visualization of nominal / current values,
operational / error messages, key allocation
►Compact enclosure for DIN-rail mounting, protection class IP00
or
control unit in protective enclosure, for machine mounting, protection class IP65
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Copyright
©2007 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 Stückl iste =====

Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0
04.07.2008 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
1Safety advices .......................................................................................................................................7
1.1 General ........................................................................................................................................... 7
1.2 Safety instructions and warnings for user .......................................................................................7
2System description...............................................................................................................................9
2.1 Introduction ..................................................................................................................................... 9
2.2 Structure and measuring principle .................................................................................................. 9
2.3 Functional sequence..................................................................................................................... 10
3Technical data .....................................................................................................................................11
3.1 Control unit A100 .......................................................................................................................... 11
3.2 T sensors ...................................................................................................................................... 13
3.2.1 Sensor T04 ............................................................................................................................... 13
3.2.2 Sensor T08 / T08S.................................................................................................................... 13
3.2.3 Sensor T15 / T15S.................................................................................................................... 13
3.2.4 Sensor T30 / T30S.................................................................................................................... 13
3.2.5 Sensor T40 / T40S.................................................................................................................... 13
3.2.6 Technical drawing T sensors.................................................................................................... 14
3.2.7 Cable allocation of T-sensors and sensor cable KS ................................................................. 14
3.2.8 Cable allocation of sensor cable KTGS-G ................................................................................ 14
4Monunting............................................................................................................................................15
4.1 Mounting of the control unit........................................................................................................... 15
4.2 Mounting of the sensors................................................................................................................ 15
4.3 Cables........................................................................................................................................... 17
4.3.1 Sensor cables........................................................................................................................... 17
4.3.2 Power supply / Control cables .................................................................................................. 17
5Electrical installation ..........................................................................................................................19
5.1 Connecting diagram...................................................................................................................... 20
5.1.1 Connecting diagram for sensors T…GS via cable KTGS-G..................................................... 21
6Start-up ................................................................................................................................................23
6.1 Keys and indicators....................................................................................................................... 23
6.2 Allocation and function of keys ..................................................................................................... 24
6.3 Switching on and Powering up...................................................................................................... 24
6.4 Operational conditions .................................................................................................................. 25
6.4.1 Undisturbed operation .............................................................................................................. 25
6.4.2 Detection of 0-sheet, 1-sheet or 2-sheet .................................................................................. 25

Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
Table of Contents 0003306 / Rev. 1.0
4 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
6.4.3 Operational disturbances.......................................................................................................... 25
6.4.4 Functional check....................................................................................................................... 25
6.5 Measurement mode ...................................................................................................................... 26
6.6 Teach-In........................................................................................................................................ 27
6.7 Changing the switching thresholds ...............................................................................................28
6.8 Teach-In with changed threshold values....................................................................................... 30
6.9 External Teach-In.......................................................................................................................... 31
7Fault messages, causes and remedies .............................................................................................33
8Maintenance ........................................................................................................................................35
9Order data ............................................................................................................................................37

Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0 Safety advices
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
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Declaration of conformity according to EC directives
Manufacturer: Roland Electronic GmbH
Otto-Maurer-Str. 17
DE 75210 Keltern
Product name: A100
Product type: R100-Serie Double Sheet Detector
Roland Electronic GmbH declare that the product listed above complies with the requirements of
the EMC directives listed below.
Applied Directives:
2004/108/EU: Generic emission standard;
EN61000-6-2: 2005 EN61000-6-4: 2001
Date of mark’s apposition: 01.10.2007
Keltern, 01.10.2007 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.
DIN EN ISO 9001
Reg.-no. 5152
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
Safety advices B0003306 / Rev. 1.0
6 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Blank page
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0 Safety advices
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
1 Safety advices
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1.1 General
This document was created with utmost care. Anyhow, faults and cases of misunderstanding
cannot be totally excluded. Please contact us in case of differences or weak understanding. We will
be pleased to assist you.
We reserve the right to improve this document at any time without announcement. No exchange of
delivered documents.
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1.2 Safety instructions and warnings for user
This handbook contains all information required for the correct operation of the R100-Serie System
family.
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. 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 forces of the sensors can cause malfunction
of cardiac pacemakers and other such apparatus!
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
Safety advices B0003306 / Rev. 1.0
8 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Blank page
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0 System description
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
2 System description
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2.1 Introduction
When automatically feeding sheets from a stack to a processing machine, it can unintentionally
happen that more than one sheet is picked up and transported. This can result in damage to the
machine, tool damage, expensive repairs and production loss. The A100 double sheet detectors
can reliably prevent from such incidents by measuring the thickness of every sheet with a single
probe sensor.
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2.2 Structure and measuring principle
A system consists of the control unit, the sensor and the sensor cable.
For performing the measurement, the destacker or feeder must move the sheet to the sensor.
During the measurement the sensor is in contact with the sheet.
The permanent magnetic sensors electronically detect the change of magnetic flux caused by the
ferromagnetic sheet. This change will be processed by the control unit and sent to the machine
controls as switching signals.
The measuring principle is based on magnetic principles. The main influencing factors for the
measured value are the magnetic properties of sheets and environment. Air gaps between sensor
and sheet surface reduce the performance of the sensor.
In order to protect the material surface, it is possible to prevent the sheet from direct contact (e.g.
with plastic coating or the like). However, this will reduce the performance of the sensor and is thus
not recommended.
Caution! The system is not suited for applications
of personal protection!
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
System description B0003306 / Rev. 1.0
10 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
2.3 Functional sequence
The transport facility places the sheet onto the sensor. Now the sensor will contact the sheet
(magnetic force of attraction) and process the sensor signal. According to the preset limits, the
respective signal output (0-sheet, 1-sheet, 2-sheet) will be activated.
If the output signal for 2-sheet is active, the PLC stops the material transport for removal of the
double sheet.
Note! “Active“ means, that the signal output will switch. In case the supply
voltage fails, all signal outputs (0-, 1-, 2-sheet) will become inactive.
The PLC must then stop the material transport.
Caution! Usually, the signal outputs of the control unit will be used for stopping
the material transport facilites and / or machines in case of double
sheet.
As soon as the double sheet is removed from the sensor(s), the signal
outputs revert instantly to normal conditions (0-sheet / 1-sheet).
Suitable control measures must ensure that the previously stopped
material transport facilites and / or machines cannot automatically
restart and thus create hazardous situations.
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0 Technical data
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
3 Technical data
Pos:14 /Doppelblech/Geräte/A100/ I100/3 Technische Daten/A100/AuswertegerätA100 @ 0\mod_1184852330828_501.doc@ 4187
3.1 Control unit A100
Supply voltage 24 V DC / 80 mA
Power consumption approx. 2 VA
Fuse 250 mA fast-blow size 1206 (SMD)
Power / switching indication 5 LEDs
Display LCD display, 2 lines, 16 chars. each
Ambient temperature 0° - 50°C (32° - 122°F) during operation
Switching outputs 0-1-2 - Sheet Open Emitters (NPN) of opto coupler outputs
Temperature depending drift of switching point ± 0,02 % / °C
Switching capacity max. 50V, max. 50mA
Measurement period Minimum sensor dwell time is 15 milliseconds.
Enclosure for DIN-rail mounting (EN50022, BS5584)
Class of protection A100 (A100-IP65) IP 00 (IP65)
Weight approx. 0,2 kg (0.44 lbs)
Connections Terminal block
Dimensions 125,4 × 103 × 38 mm (H × W × D)
125,4
46,5
103
fault
power
2 sheet
1 sheet
0 sheet
Fig. 1: Dimensions of A100 (for mounting on DIN-rail) A100 abmessungen.wmf

Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
Technical data B0003306 / Rev. 1.0
12 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Description
1 Screw fitting M16
for control cable
Wrench size 19 mm
2 Screw fitting M12
for sensor cable
Wrench size 15mm
90
30
40
M16×1,5
SW 19
M12×1,5
SW 15
120
114
90,5
135
154
148
160
35
38
12
Deckel / Lid
fault
power
2 sheet
1 sheet
0 sheet
4,2 Ø
Fig. 2: Dimensions of A100-IP65 (in protective enclosure IP65) A100 in multibox IP65.wmf
Pos: 15 /Doppelblec h/Sensoren/T-Sens oren/T-Sensoren T echnische Daten @ 0\ mod_113933048076 5_501.doc @ 1421

Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0 Technical data
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
3.2 T sensors
The sensors are available either with fixed cable or plug connector.
The pluggable version has the addition S(e.g. T15 -> T15S)
For all sensors: Ambient temperature 0 – 50 °C (during operation)
The useful sheet thicknesses depend very much on the properties of the material to be measured,
they can deviate from the values stated below.
3.2.1 Sensor T04
Technical data
Single sheet thickness: min. 0,04 mm max. 0,4 mm (.016 in.)
Min. adhesive force on axial tear-off 1,5 kg (3.3 lbs.)
Weight: 0,15 kg (.33 lbs.)
3.2.2 Sensor T08 / T08S
Technical data
Single sheet thickness: min. 0,08 mm max. 0,8 mm (.032 in.)
Min. adhesive force on axial tear-off 8 kg (17.6 lbs.)
Weight: 0,32 kg (1.45 lbs.)
3.2.3 Sensor T15 / T15S
Technical data
Single sheet thickness: min. 0,1 mm max. 1,5 mm (.06 in.)
Min. adhesive force on axial tear-off 15 kg (34 lbs.)
Weight: 0,38 kg (.83 lbs.)
3.2.4 Sensor T30 / T30S
Technical data
Single sheet thickness: min. 0,2 mm (.012 in.) max. 3,0 mm (.12 in.)
Min. adhesive force on axial tear-off 35 kg (77.2 lbs.)
Weight: 1,1 kg (2.43 lbs.)
3.2.5 Sensor T40 / T40S
Technical data
Single sheet thickness: min. 0,3 mm (.01 in.) max. 4,0 mm (.16 in.)
Min. adhesive force on axial tear-off 55 kg (122 lbs.)
Weight: 2,3 kg (5.1 lbs.)
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
Technical data B0003306 / Rev. 1.0
14 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
3.2.6 Technical drawing T sensors
Description
The sensors T04, T08, T15, T30,
T40 are equipped with a fixed
cable for terminal connection.
Standard cable length is 2 meters,
lengths up to 20 meters upon
order.
The sensors T08S, T15S, T30S,
T40S are without cable, but with
build-in socket at the sensor.
T
04
T
08
T
1
5
T30S T40S
45 55 60
80
100
Ø18 Ø28 Ø34
Ø54 Ø70
Ø28
Ø28
4
7
12
50
T
30
T
40
80
100
Ø54 Ø70
T08S T15S
55 60
Ø28 Ø34
Ø28
Ø28
Fig. 3: Dimensions of T sensors T-Sensoren_Abmessungen.wmf
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3.2.7 Cable allocation of T-sensors and sensor cable KS
1
2
34
ws (weiß / white)
gn (grün / green)
br (braun / brown)
ge (gelb / yellow)
ge-gn (gelb-grün / yellow-green)
[Schirm / Shield]
ws (weiß / white) [1]
gn (grün / green) [2]
br (braun / brown) [3]
ge (gelb / yellow) [4]
ge-gn (gelb-grün / yellow-green)
[Schirm / Shield]
Fig. 4: Allocation of sensor cable KS Kabel_KS.wmf
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3.2.8 Cable allocation of sensor cable KTGS-G
1
2
3
4
br (braun / brown) [1]
ws (weiß / white) [2]
bl (blau / blue) [3]
sw (schwarz / black) [4]
Fig. 5: Allocation of sensor cable KTGS-G Kabel_KTGS-G.wmf
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0 Monunting
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
4 Monunting
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4.1 Mounting of the control unit
The system is available in 2 different enclosures:
• for DIN-rail mounting (EN50022, BS5584), protection class IP00.
• for machine or frame mounting, in plastic enclosure with transparent lid,
protection class IP65.
The system should be mounted in such a way that the indicators and operating keys in the front of
the unit are always well visible. The place should be safely accessible and free from obstruction.
The system must not be exposed to extreme temperature, irradiation or mechanical load.
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4.2 Mounting of the sensors
Caution! Sensors of the T series contain permanent magnets.
During the handling the risk of squeezing and clamping exists.
The sensors must be kept away from magnet sensitive
media (cheque cards, hard disks, diskettes…) and
systems (cardiac pacemakers, solenoid switches).
Sensors with different sizes are available. The size determines the thickness measuring range and
the magnetic force of attraction. This force is proportional to the thickness of the measured sheet
metal.
When removing the sensor off the sheet or putting it on, the force of attraction must be overcome
by mechanical, hydraulic or pneumatic means. The force of attraction can be reduced by creating a
small air gap between sensor and sheet metal (recessed installation, use of a roller block).
Note! An air gap reduces the measurement capacity.
Mounting:
The place of mounting depends on the destacking and feeding equipment. In principle a distance of
more than 0.5m must be kept from magnetic/electromagnetic interference sources like e.g. valve
coils, transportation magnets, inductive proximity switches or the like.
The sensor can be mounted in any direction, either over or under the sheet metal.

Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
Monunting B0003306 / Rev. 1.0
16 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Recommendable are:
• Flush mounting into the material slide either tight fit or interference fit.
Advantage: no wear and no deposite of chips and particles.
Recessed installation is possible; however, care should be taken that no chips and
particles collect in the recess (possibly fill up recess with non-ferrous-magnetic material).
• Spring suspended sensor bracket for use with thick sheet metals.
Advantage: the sensor can adapt to bowed sheet metal, thus avoiding unintended air gaps.
The minimum dwell time of the sheet metal on the sensor is 15ms.
Fig. 6: Flush and recessed mounting of sensors BündigeMontage_EC-Sonden.wmf
Note! If the sensor is used for double sheet detection of preformed sheet
metals, an air gap between first and second sheet can develop; thus
the double sheet condition might not be detected. This must be
considered when selecting the place for mounting the sensor, select
the next larger sensor if the occasion arises.
Opposite of the sensor face there must be no other ferromagnetic
material within the distance of 1.5 x sensor diameter, because this will
severely affect the measurement. The diameter of the sensor should
correspond to the minimum measuring area of the sheet.
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0 Monunting
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
4.3 Cables
All cables must be professionally installed. Bending radii (see data sheets of manufacturer) must
be adhered. The cables must be protected from chafing and buckling by suitable installation.
Damaged cables must not be used and need to be replaced immediately.
If the recommended cables cannot be used (e.g. due to missing UL/CSA approval), substitutes
should be cleared with Roland Electronic.
Note! Keep the sensor cables as well as the power supply / control cable
away from unshielded cables with strong electro magnetical
interference potential (e.g. servo motor and power cables).
4.3.1 Sensor cables
The sensors are available either with plug connector or with fixed cable. For connecting, only the
supplied shielded sensor cables may be used. In the standard version those cables are not suitable
for robot or drag-chain operation.
The cable shield is connected at both sides.
4.3.2 Power supply / Control cables
Suitable power supply / control cables:
- Type H05VV5-F (Lapp Ölflex® 140) with leads 0.5 mm²
- Type H05VVC4V5-K (Lapp Ölflex® 140CY), shielded, with leads 0.5 mm².
A shielded cable must be used if the environment has high electromagnetical interference signals.
This cable shield must be grounded at the machine side, not at the control unit side.
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
Monunting B0003306 / Rev. 1.0
18 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
Blank page
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
B0003306 / Rev. 1.0 Electrical installation
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
5 Electrical installation
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The system should be installed only by professional electricians. The cables must correspond with
the specifications stated in section „Cables“.
Note! For connecting the cables to the
control unit, insulated wire-end
ferrules must be used.
The required supply voltage is 24 V DC and should be supplied from the associated machine
controls.
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Manual
Double Sheet Detector R100-Serie A100
for single sided sensors
Electrical installation B0003306 / Rev. 1.0
20 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone [phone] · Fax [phone]
5.1 Connecting diagram
Connections A100
+24 V
GND
grün-gelb green-yellow
Teach-In 2-Blech / 2-sheet 1-Blech / 1-sheet 0-Blech / 0-sheet +24V COMMON
zum Sensor
to sensor
zur SPS
to PLC
braun / brown gelb / yellow weiß / white grün / green Schirm / shield
–V
H
+V
H
+I
H
–I
H
PE
Note! The shielding of the cable must always be connected.
The protective lead (PE) must always be connected, it should
never be missing.
Internal circuit of the PLC connection (terminals 4 to 8)
Teach-In
2-Blech 2-sheet 1-Blech 1-sheet 0-Blech 0-sheet
COMMON +24V max.
45678
Fig. 7: Connecting diagram for A100 A100 anschlußschema.wmf A100 anschlussleiste.wmf