double sheet detector r1000 series udk20 electro magnetic ... · double sheet detector r1000 series...

Double Sheet DetectorR1000 series UDK20Electro magnetic and eddy current principlesintegrated in one sensor -microcontroller based

Only one linearized sensor for ferrous and non-ferrous materials

FE materials for sheet thickness up to max. 4 mm (.16 in.)

NF materials for sheet thickness up to max. 4 mm (.16 in.) depending on electrical conductivity

• Direct connection of up to 2 sensors to a unit possible (version 2 PW)

• Programmable for 255 different sheet thicknesses and materials

• Calibration with a teach-in procedure

• Digital display of sheet thickness and operational parameters

• Monitoring of over-gauge and under-gauge limits

• Monitoring of operating voltage and sensor

• Galvanically insulated 9-bit PLC input interface

• Galvanically insulated 4-bit PLC output interface

• Selectable equipment interfaces:

- Data communication and data backup via (optional) potential-free RS232 interface

- Relay outputs or opto-coupler outputs for under-gauge, nominal gauge, over-gauge and enabling

ROLAND

DOUBLE SHEET CONTROL UDK20

> Panel mount enclosure> All common fieldbus standards

NOW AVAILABLE:

© 2006 Roland Electronic GmbH.

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.

ROLAND OPERATING INSTRUCTIONSDOUBLE SHEET DETECTOR R1000 UDK20

Rev. 1.0

ROLAND ELECTRONIC GMBH · Otto-Maurer-Str. 17 · D-75210 Keltern · Telefon (0049) (07236) 9392-0 · Telefax (0049) (07236) 9392-33

Declaration of conformity according to EC directives

Manufacturer: Roland Electronic GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern

Product Name: Double Sheet Detector

Product Type: R1000 UDK20

Roland Electronic GmbH declares that the product above complies with the requirements of the ECCdirectives for harmonizing the legal code within the member states.The conformity with the directives of the product listed above is confirmed by complying fully with theharmonized European comply standards below.

89/336/ECC: Directive regarding emission standard;modified by Directive RL 91/263/ECC, 92/31/ECC and 93/68/ECC.

EN61000-6-4: 2001 EN61000-6-2: 2001

Year of apposition of CE mark: 2006

Keltern, 01.09.2006 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 aparticular purpose especially as it may relate to product liability.The safety instructions and warnings must be observed.

DIN EN ISO 9001 / Reg.-Nr. 5152


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Rev. 1.0 / 08.11.2006

Table of Contents

Declaration of conformity according to EC directives ................................................................ Page3

1. Safety instructions and warnings for user ............................................................................ Page91.1 Intented use ..................................................................................................................... Page9

2. Technical data ........................................................................................................................ Page112.1 Sensors .......................................................................................................................... Page112.2 Sensor performance data for ferrous (FE) materials ...................................................... Page122.3 Sensor data for non-ferrous (FE) material ...................................................................... Page142.4 Versions of the control unit UDK20 ................................................................................ Page152.5 Technical data control unit UDK20 ................................................................................. Page162.6 Technical data SSBUDK10 (Sensor switch box) ............................................................ Page172.7 Sensor Cables ............................................................................................................... Page17

3. System description ............................................................................................................... Page193.1 General hints for process security ................................................................................. Page193.2 Control unit ..................................................................................................................... Page203.3 Parameters of the control unit ........................................................................................ Page20

3.3.1 System parameters: .......................................................................................... Page213.3.2 Program parameters .......................................................................................... Page23

3.4 Typical Application examples ......................................................................................... Page25

4. Mounting ................................................................................................................................ Page314.1 General mounting instructions ....................................................................................... Page314.2 Dimensions of the enclosure .......................................................................................... Page324.3 Sensor mounting ............................................................................................................ Page35

4.3.1 Spring loaded sensor bracket SHS42G-FB (with bellow suction cup) ................ Page364.3.2 Spring loaded sensor bracket SHS42GS (with flat suction cup) ........................ Page374.3.3 Spring loaded sensor bracket SH42GS ............................................................. Page394.3.4 Clamping device SHK ........................................................................................ Page404.3.5 Incorrect installation of the PW sensors ............................................................ Page414.3.6 Electromagnetic interference ............................................................................. Page41

4.4 Mounting of the Sensor Switch Box SSBUDK10 ........................................................... Page42

5. Electrical installation ............................................................................................................ Page435.1 General instructions ....................................................................................................... Page435.2 Allocation of connections ............................................................................................... Page44

5.2.1 Sensor connection - 1st sensor ......................................................................... Page465.2.2 Sensor connection - 2nd sensor ........................................................................ Page475.2.3 Connection of Sensor Switch Box (SSB) .......................................................... Page485.2.4 Connection of RS232 ......................................................................................... Page485.2.5 Central connection (central plug) ....................................................................... Page495.2.5.1 Machine grounding............................................................................................. Page495.2.5.2 Supply voltage ................................................................................................... Page495.2.5.3 Data inputs / outputs to PLC ............................................................................. Page505.2.6 Connection of the PW42GS sensor and the sensor cable ................................. Page545.2.7 Cable SVCPWS-SSBUDK10 ............................................................................. Page55


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5.3 Connection diagrams ..................................................................................................... Page565.3.1 UDK20-XX-S-XX with one PW42AGS sensor ................................................... Page565.3.2 UDK20XX-S-XX with SSBUDK10 and four PW42AGS sensors ........................ Page575.3.3 UDK20-2PW-XX-S-XX with two PW42AGS sensors ......................................... Page58

5.4 Internal wiring of the Sensor Switch Box SSBUDK10 .................................................... Page59

6. Communication with the PLC .............................................................................................. Page616.1 External control .............................................................................................................. Page61

6.1.1 System test ....................................................................................................... Page626.1.2 Measurement menue selection .......................................................................... Page636.1.3 Measurement Start / Stop ................................................................................. Page656.1.3.1 Single measurement .......................................................................................... Page656.1.3.2 Continuous measurement .................................................................................. Page676.1.4 External zero adjust (via PLC inputs) ................................................................ Page696.1.5 External Teach-in (via PLC inputs) ..................................................................... Page706.1.6 Typical measuring cycle when using the unit for destacking ............................. Page71

7. Start-up................................................................................................................................... Page737.1 Initial Start-up ................................................................................................................ Page737.2 Operation ....................................................................................................................... Page747.3 Configuration menu ........................................................................................................ Page757.4 General information regarding configuration ................................................................... Page767.5 Changing, adjusting or checking the configuration ......................................................... Page767.6 System parameters ........................................................................................................ Page777.7 Program parameters ...................................................................................................... Page84

7.7.1 Program parameter 7: Zero adjust .................................................................... Page867.7.2 Program parameter 8: Teach-in ......................................................................... Page87

7.8 Data backup via serial RS232-interface (only for C-versions) ........................................ Page90

8. Operation ............................................................................................................................... Page918.1 Abbreviated operating instructions ................................................................................. Page918.2 Entering a new measurement program ........................................................................... Page93

9. Fault messages, causes and remedies ................................................................................ Page959.1 Fault messages of the Sensor Switch Box .................................................................... Page969.2 Memory faults (faults no. 1 to 24) ................................................................................... Page979.3 Zero adjust faults (fault no. 25 to 29) .............................................................................. Page989.4 Teach-in fault (faults no. 30 to 39) .................................................................................. Page989.5 RS232 Transmission faults (faults no. 40 to 49) ............................................................. Page989.6 Faults due to measuring operation (faults no. 50 to 54) .................................................. Page999.7 Keyboard faults (fault no. 55 to 59) ................................................................................. Page999.8 Faults due to operating voltage (faults no. 60 to 64) ....................................................... Page999.9 Sensor Switch Box faults (faults no. 65 to 69) ............................................................... Page999.10 Faults parallel PLC inputs (faults no. 70 to 79) ............................................................. Page1009.11 Other faults (80 to XX) ................................................................................................. Page100



Rev. 1.0 / 08.11.2006

10. Maintenance ......................................................................................................................... Page10110.1 Sensor exchange ......................................................................................................... Page10110.2 Exchange of a Control unit ........................................................................................... Page10210.3 Exchange of the fuses ................................................................................................. Page10310.4 Data back up via serial interface (only for C-version units) .......................................... Page10310.5 RPP-XP software (WinXP version) .............................................................................. Page10410.6 Spare parts .................................................................................................................. Page107

11. Technical information ......................................................................................................... Page10911.1 Exchange of a R1000 UDK10 control unit against a R1000 UDK20 control unit .......... Page10911.2 System configuration ................................................................................................... Page109

12. Order data ............................................................................................................................ Page11012.1 Versions of UDK20 ....................................................................................................... Page11012.2 System accessories .................................................................................................... Page11012.3 Sensors and accessories ............................................................................................. Page11112.4 Cables .......................................................................................................................... Page11112.5 Cable plugs and cable sockets .................................................................................... Page11212.6 Other accessories ........................................................................................................ Page112


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Rev. 1.0


1. Safety instructions and warnings for user

This handbook contains all necessary information for the correct operation of the R1000 family of systems.It is intended for usage by technically qualified personnel.Unauthorized tampering with the unit, especially ignoring the warnings in these operating instructions, cancause malfunction and damage to the unit.Only authorized personnel may perform changes to the unit and make cable connections (especially the powersupply).Should measurements within the unit be required (e.g. for service or repair), then all customary accidentprevention procedures must be observed. Only professional electrical tools should be used.

Note: Factory system adjustments, especially the upper and lower limits, are madeto provide optimal machine protection. Deviations from factory adjustments couldimpair the protection.

1.1 Intented use

Flexible manufacturing systems in the sheet processing industry require reliable Double Sheet Controlsystems, in order to protect presses and other sheet processing machines against damage caused byfeeding multiple sheets.The Double Sheet Detector R1000 UDK20 was specifically developed for this technical environment.Depending on the application (type of material, thickness, sensor gap) the UDK20 can be used with one ormore sensors. The reliable function of the Double Sheet Detector depends therefore markedly on theselection of the correct sensors and the mounting of the sensors.


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2. Technical data

2.1 Sensors

The sensor description has the following code:

Picture: Sensor description

Sensor PW42AGS

PW42AGS PW42AGSPW42AGS

All dimensions are in mmTolerance ± 0.15mm

Measure with free space for connecting plug to sensor

Picture: Sensor dimensions PW42AGS

Ambient temperature: 0 - 60 °C (32 - 140 °F)Weight: 0.45 kg (1 lb)Protection category: IP65

PW42AGS

electromagnet

eddycurrent

diameter threadedbody

quickdisconnect

version


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2.2 Sensor performance data for ferrous (FE) materials

The following diagram shows the reaction time of the system on detecting double sheet, depending on thenominal sheet thickness and the selected upper switching limit (UL) 150% or 120%.

Example: Nominal thickness 1.5 mm = 100% (.06 in. = 100%), measurement with 1 sensor.

The maximum system reaction time for detecting the exceeding of the double sheet threshold is 63 ms at120% UL. This means, it takes 63 milliseconds after having recognized the measurement start signal untilthe result is available at the output.The data for 2 sensors apply in the so-called sequencer mode.

40

50

60

70

80

90

100

110

120

130

140

150

160

170

4,0 Single sheet thickness(nominal thickness) [mm]Normal working range

(0 to .16 inch)

3,53,02,52,01,51,00,50

Sys

tem

reac

tion

time

[ms]

150%

120%

PW42AGS

2 sensors

1 sensor

Picture: System reaction time for ferrous material

Double sheet thresholds above 120% reduce the performance of the system with regard to air gaps betweenthe sheets and increase the systems reaction time according to the diagram.

Air gaps influence the performance negatively because air has - in contrast to steel - a high resistance tothe magnetic flux. Therefore, air gaps reduce the performance of the system considerably(see chapter 3.1 “Measuring principle and conditions influencing measurement accuray“).

For reliable double sheet monitoring there must not be any air gap between sheet and sensor as well as noair gap between the sheets. This aspect has to be considered when mounting the sensors and selectingthe place of installation. The influence of air gaps can be read from the following diagrams.


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Max. air gap between sensor and 1st sheet (1st gap)

0,2

0,4

0,6

1,4

1,6

1,8

2,0

2,2

0,0

1st a

ir ga

p [m

m]

0,8

1,0

1,2

PW42AGS

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 Sheet thickness [mm]

Max. air gap between 1st and 2nd sheet (2nd gap)

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 Sheet thickness[mm]

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

9,0

0,0

2nd

air

gap

[mm

]

PW42AGS

1.

2.


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2.3 Sensor data for non-ferrous (FE) material

The amount of eddy current generated and the corresponding energy absorption is directly related to theelectrical conductivity. High values of electrical conductivity and the corresponding strong eddy currentsreduce the controllable sheet thickness.The eddy current principle is more forgiving with regard to air gaps than the electromagnetic principle.However, for most reliable performance precaution should be taken to avoid air gaps between sensor andsheet. The permissible air gaps between first and second sheet can be slightly higher than for steel.

Note: The system reaction time for non-ferrous materials is constant at 85milliseconds. This applies for measurements with 1 sensor as well as for measurementswith 2 sensors (in sequencer mode).

Material Conductivity (MS)

Max. thickness f. single sheet

(mm) Austenite 1,41 4,0 Bronze 8,5 4,0 Zinc 16,3 4,0 AL-Alloy 18,2 4,0 AL-Alloy 25,2 4,0 AL 34,2 4,0 CU-Alloy 43,0 3,5 CU 57,5 3,0

Table: Max. sheet thickness for non-ferrous material (selection)


Rev. 1.0


2.4 Versions of the control unit UDK20

The product designation is coded as follows :

UDK20-xxx-x-x-S-xx

Version B: Memory for 255 Parameter sets (nominal thicknesses and upper and lower limit values).Programming via pushbuttons.Adressing via 9 potential free control inputs 24 VDC with common potential.

Version C: As version B, but additionally:1 potential free RS232 interface for data backup.

From the code shown above the following versions of the control unit will result. All versions are available.

)selpmaxe(tinulortnoc02KDUehtfosnoisreV

)BSSaiv4.xam(rosnes1htiw srosnes2otpuhtiw

erusolcnelairtsudnini tnuometalptnorfrof erusolcnelairtsudnini tnuometalptnorfrof

S-R-B-02KDU PF-S-R-B-02KDU S-R-B-WP2-02KDU PF-S-R-B-WP2-02KDU

S-O-B-02KDU PF-S-O-B-02KDU S-O-B-WP2-02KDU PF-S-O-B-WP2-02KDU

S-O-C-02KDU PF-S-O-C-02KDU S-O-C-WP2-02KDU PF-S-O-C-WP2-02KDU


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2.5 Technical data control unit UDK20

Operating voltage: 24 VDC, +6V / -2 VPower consumption: < 60 W (measuring mode < 60 W, standby mode < 10 W)Switch on current: approx.: 10 A for 1 msExternal Fuse: 5 A, slow-blowWeight: approx.: 1.2 kg (2.65 lb)Ambient temperature: 0 - 50 °C (32 - 122 °F)

Wall mount enclosureDimensions (without connected plugs): approx.: 205 x 140 x 80 mm (L x W x H)

approx.: 8.07 x 5.51 x 3.15 inch (L x W x H)Dimensions (with PG connected plugs): approx.: 205 x 220 x 80 mm (L x W x H)

approx.: 8.07 x 8.66 x 3.15 inch (L x W x H)Protection category: IP65

Front panel enclosureDimensions: approx.: 180 x 180 x 70 mm (L x W x H)

approx.: 7.09 x 7.09 x 2.76 inch (L x W x H)Protection category: IP40 (inside), IP65 (front cover)

Additional characteristics

• 255 parameter sets memory

• Programming via push buttons

• 9 galvanically insulated optocoupler inputs 24 VDC with joint commonSpecification:- min. switching voltage HIGH: 18 VDC- max. switching voltage HIGH: 30 VDC- min. switching voltage LOW: 0 VDC- max. switching voltage LOW: 8 VDC

• 4 potential free outputs with common positive supply voltageSpecification:Relais version:- switching outputs: potential free relay opening contacts- max. switching voltage: 250 V AC- max. switching current: 1 A- max. switching capacity: 240 W / 200 VAOpto coupler version:- switching outputs: emitter and collektor open- max. switching voltage: 50 VDC- max. switching current: 150 mA- max. switching capacity: 100 mW

Attention: With inductive load please use unloading diodes. Otherwise the signal output can bedamaged by voltage surges caused by switching off inductive loads.


Rev. 1.0


• RS232 interfaceSpecification:

- Baudrate: 4800- Data Bits: 8- Parity-Bit: None

- Stop-Bit: 1

- Hardware Handshake: None

2.6 Technical data SSBUDK10 (Sensor switch box)

Operating voltage: 24 VDC, supplied from the UDK20 control unitPower consumption: < 10 WProtection category: IP65Weight: 1.4 kg (3 lb)Ambient temperature: 0 - 50 °C (32 - 122 °F)

2.7 Sensor Cables

Cable types:SCPWS-GG, SCPWS-GW: Superflex-C (Y) PURKOMBI 2 x 1 mm2 + 4 x 2 x 0,25 mm2, Lütze Company

Specification:

The selected cables have the following properties:

• Drag chain suitable

• Oil resistant

• PUR-cable sheath

• DIN color code

• Tinned copper shieldFor more information please refer to specifications of Lütze Company representations in your country.


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OPERATING INSTRUCTIONSDOUBLE SHEET DETECTOR R1000 UDK20

Rev. 1.0


ROLAND

3. System description

Flexible manufacturing systems in sheet metal processing require automated and reliable double sheetcontrol systems in order to safeguard presses and other processing machinery against damage due tomultiple sheets. This applies not only to steel but also to aluminum and other non-ferrous metals as wellas non-magnetic stainless-steel (austenite), materials as they are increasingly being used in automotiveapplications. In addition, the production of so-called “Tailor Welded Blanks“ (TWB) has created complexmanufacturing systems with special requirements regarding automated double sheet control systems.

The Double Sheet Detector UDK20 was specifically developed for this technical environment. The specialfeature of the system is the ability to monitor ferrous and non-ferrous materials with one sensor only - thePW42AGS.A system for one measuring point consists of the following three components:

• Control unit

• Sensor PW42AGS for ferrous and non-ferrous materials

• Sensor cable

3.1 General hints for process security

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. For measuring procedures with single-sided contacting sensors the air gap between sensor and material surface is a decisive criterion.Air gaps varying from measurement to measurement will cause varying mesuring results. Basically, suchsituations are bad, since in such cases the user is inclined to decrease the under-gauge threshold and toincrease the over-gauge threshold. On doing so, the user puts up with the drastically increasing risk of notdetecting a double sheet.The following external factors decisively influence the stability of measuring results and need to beconsidered for operation of a double sheet detector:

• the air gap between sensor and material surface

• the electrical and magnetical characteristics of the material

• the tolerance in material thickness

From this some simple rules derive, which enable a large degree of process security when abided by:

• Always care for good contact of the sensor with the material !

• Use the same program to monitor materials of the same thickness and alloy !

• Adjust the switching threshold as tight as possible !


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Furthermore it is necessary that the control checks all status signals of the UDK20. The 0-sheet signal alsoneeds to be checked. 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 deposited, re-pickedand measured again.

• The control needs to evaluate all status signals !Checking-up through the 0-sheet signal is to assure that a sheet really is in front of the sensor duringmeasuring. If 0-sheet occurs while measuring, the measurement is not correct. For example, a defectivesensor holder might prevent the sensor from contacting the sheet. Monitoring the sheet thickness wouldthen only be performed apparently. In case of double sheet fatal consequences could then result.

3.2 Control unit

The UDK20 is based on the product platform R1000.Major features of the control unit:

• Programmable for 255 different sheet thickness and materials

• Calibration by teaching procedures

• Digital display of sheet thickness and operating parameters

• Monitoring of over- gauge and under- gauge limits

• Monitoring of operating voltage and sensor cable (for broken wire)

• Optocoupler for direct I/O control via the PLC for fast measurement operations

• Data storage via serial interface

3.3 Parameters of the control unit

The UDK20 provides for extensive configuration. So, different customer requirements can be served.Configuration is performed by setting system parameters and program parameters. System parameters areset only once on commissioning, and will then remain unchanged. Program parameters contain items whichare material and job depending, and enable individual adaptation to the measuring task.


Rev. 1.0


ROLAND

3.3.1 System parameters:“Language“System languages available for operating the unit via display and keyboard:German / English / Spanish / Italian / French.

“Sensor type“At the time of editing the sensor type PW42A is available. For this sensor a characteristical curve forlinearization purposes exists.

“Number of sensors“Defines the number of connected sensors. Those sensors are then available for measuring. At a 2-channel unit (UDK20-2PW...) max. 2 sensors can be connected, at a 1-channel system with sensor-switch-box max. 4 sensors can be connected.

“Indication in“Switches the indication of the thickness values on the display between mm <=> inch.

“Measurement operation“Sets how the measuring is to be triggered. The following modes are available:

• DemoThe demo mode is only intended for test and demonstration purposes. In this mode mesauring isperformed until the demo mode is switched off again. For doing so, another mode must beselected. The repetition time of the measuring is 1 second for FE material, for NE and LMmaterial it is below 0.085 seconds.

• Ext. Single (default setting)Here a single measuring is performed. For doing so, the signal “Measuring start“ must beexternally fed. Another measuring requires a new flank of the “Measuring start“ signal.

• Ext. PermanentlyHere the measuring is maintained as long as the signal “Measuring start“ is fed. The repetitiontime of the measuring is 0.5 seconds for FE material, for NE and LM material it is below 0.085seconds.

“FE Measuring fast/normal“For time-critical applications the measuring time can be slightly shortened for measuring FE material. If“fast“ is selected and double sheet occurs, the measuring is terminated on reaching the upper switchlimit, and the information “2-sheet“ is released. If “normal“ is selected, the measuring will be executedto the end and the measured thickness will be displayed.

“FE-T-limit“On teaching-in of FE material the deviation of the measured thickness from the nominal thickness willbe monitored. Certain ferro magnetical materials show larger deviations as usual. In these cases the33%/142% setting makes sense. Default setting is 66%/125%. Both values represent the permittedrelative range of measured to nominal thickness. If the measuring value is not within this range, theteach-in cannot be performed and will be aborted with an error message.


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“CLR parameter (Clear Program Parameter)“Deletes all program parameters. For doing so, the parameter needs to be set to “yes“. Executing thecommand requires several minutes, since the program memory will completely cleared. All programparameters will be reset to the default values and existing teach-in data will be deleted. Using thisfunction only makes sense if a unit is to be newly used for another machine.

“Password yes/no“Switches the password request on/off. If the password request is set “on“, the system / programparameters can only be changed after the password has been entered.

“External Alignment“Sets whether an external teach-in / zero adjust is to be possible. If “yes“ is set, the PLC can trigger theprocedure via the inputs “Teach-In 0-, 1-sheet“. Default setting is “no“.

• The external alignment may only be performed under supervision of an operator.

“Output level“Sets the output voltages for outputs 0-,1-,2-sheet führen. Default setting is 0 V DC.

“Diagnosis factor“Diagnosis of the factors located during the Teach-In. No default setting.

“W-Diagnosis“Diagnosis of the measuring values for NF material type. No default setting.

“UDK20-PR-S-(1)““SV:xx HV:xx“Identification of unit. Needs to be at hand for telephone support.

“Version“Indication of the version of the unit. Factory setting, do not change !


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3.3.2 Program parametersThe sensor is operated in two different modes. For FE material an electro magnetical method – called“P“ measurement – is used. For the P measurement a compensation curve for linearization exists. Thecompensation curve fits to ST37 steel. Other steel alloys resp. magnetical materials deviate from thiscurve. This causes measuring results which can deviate for more than 5% from the real sheetthickness. In such cases it is useful to calibrate the unit (later merely called “Teach-In“).For NF material an eddy current method – called “W“ measurement – is applied. Here a Teach-In isrequired, since there is no general linearization curve.In order to avoid frequent Teach-In procedures for different materials and thicknesses, the unit providesfor 255 program memories. Every such memory consists of a data set with the following parameters.

“Sensor number“For multi-channel systems (e.g. UDK20-2PW…) or a system with external sensor switch box SSB-UDK10 the selected sensor must be entered.

“Material“Selects the material type FE, NF or LM (slightly magnetical stainless steels). In case of unknownmaterial AUTO must be chosen. For all settings (except for FE) a Teach-in is required.

“Nominal measure“Changes the nominal measure. It can be shown in mm or inch.Default setting either 0,03mm or 0,001 inch.

“TO“ and “TU“Changes the limit values for the lower and upper switching threshold. The values can be entered eitherin % or in mm/inch. On these thresholds the status signals depend. In a window comparator the threesignals will be generated from the measuring signal.The signal “0-sheet“ is generated when the measuring signal falls short of the lower switching threshold.The lower switching threshold TU can be set from 1...99%. The signal “2-sheet“ is generated when theupper switching threshold is exceeded. The upper switching threshold TO can be set from 100...150%.If the measuring value is within both limits, the signal “1-sheet“ is generated.

Fig.: Visualization of switching thresholds

a = Signal range for 0-sheetb = Signal range for 1-sheetc = Signal range for 2-sheetTO = switching threshold for upper limitTU = switching threshold for lower limit


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The preset values (TO=120% resp. TU=80%) should only be changed under the following aspects:1. the 1-sheet range becomes restricted, since the measuring values are very stable. Thus the

process security increases. The restriction can be done by decreasing the TO value, byincreasing the TU value, or both.

2. the 1-sheet range becomes extended for a time. Thus the process security decreases. Such anaction should only be performed in exceptional cases, the user has to decide about that.Extending the 1-sheet range is commonly considered due to mechanical problems (air gap,uneven sheets). This measure prevents the machine from standstill, until the mechanical problemis solved.

“Zero adjust“Before commissioning a new system, after having exchanged a sensor or a sensor cable or a control

unit, a zero adjust must be performed. This zero adjust eliminates the variation of the sensors.The sensors can be zero adjusted “separately“ or “all in one stroke“.

• The zero adjustment is valid for all programs and should be performed only once !

“Teach-In“Initiates a Teach-In via keyboard. Teach-In is required for NF material and – partially – also for FEmaterial. Depending on status and material the items “ok“/“missing“/“on“/“without“ can be selected.

• The value “ok“ indicates that a Teach-In has been successfully performed.

• The value “missing“ indicates that a Teach-In is required and was not yet performed.This item does not appear for “Material“ setting “FE“.

• The value “on“ indicates that a Teach-In is currently being performed.

• The value “without“ indicates that a Teach-In is not necessarily required.This item appears only for “Material“ setting “FE“.


Rev. 1.0


ROLAND

3.4 Typical Application examples

UDK20-X-X-S-XX with 1 sensorConnection of 1 sensor PW42AGS to the control unit.

Picture: Application with 1 sensor PW42AGS


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UDK20-X-X-S-XX with Sensor Switch Box (SSB) and 4 SensorsConnection of max. 4 sensors to the control unit via Sensor Switch Box.

Picture: Application with up to 4 sensors PW42AGS

Attention! Using the Sensor Switch Box is only possible in combination with theUDK20-X-X-S-X, but not with the UDK20-2PW-X-X-S-X.

The optional Sensor Switch Box (SSB) permits connecting of max. four sensors PW42AGS to oneUDK20-X-X-S-X. These sensors cannot be operated parallelly via SSB but only sequentially via pro-gram switchover.


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ROLAND

UDK20-2PW-X-X-S-XX with 2 sensorsDirect connection of max. 2 sensors PW42AGS to the control unit.

Picture: Application with 2 sensors PW42AGS

The switching of the sensors can be made as follows:a) with the so-called sequencer mode (automatic switching by the unit)b) by program switching


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Explanation of “summary output“ for 0-sheet, 1-sheet and 2-sheet:

If the unit is used in seqencer mode (program with two sensors), the measurement result is formed assummary output. The priorities are:

1. If one or more sensors detect double sheet, the summary output is 2-sheet.2. If all sensors detect 1-sheet, the summary output is 1-sheet.3. Otherwise the summary output is 0-sheet.

Sensor 1 Sensor 2 Output 0-sheet 0-sheet 0-sheet 0- sheet 1-sheet 0-sheet 0- sheet 2-sheet 2-sheet 1- sheet 0-sheet 0-sheet 1- sheet 1-sheet 1-sheet 1- sheet 2-sheet 2-sheet 2-sheet 0-sheet 2-sheet 2-sheet 1-sheet 2-sheet 2-sheet 2-sheet 2-sheet

Table: Truth table for summary output


Rev. 1.0


ROLAND

Method a)Advantageous when measuring the same sheet thickness with each sensor. In contrast to the method b)addressing of each sensor is done automatically by the UDK20. The sequence of the sensors ispredetermined in the program.

Advantage: Very fast measurement are possible, smaller software effort on the PLC side.Disadvantage: There is only 1 "summary output" for the active sensors available. For the summary

output the following priorities apply: " 2-sheet prior to 0-sheet" and "0-sheet prior to 1-sheet".

In addition to the selection by sensor number (see system configuration "number of sensors"), the followingsequences for the selection are available: Sensor 1 + Sensor 2


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Method b)Meaningful, if the sheets to be monitored by the various sensors have different sheet thicknesses. Alsosuitable if the nominal thickness changes from cycle to cycle.For this procedure the respective parameter set (program) must contain nominal thickness and sensornumber. The selection of the program is then performed by the PLC.Disadvantage: A Long time is required for switching the program via the parallel interface.


Rev. 1.0


4. Mounting

The mounting of the Double Sheet Detector R1000 UDK20 determines the measurement accuracy and thereliability of operation. The system was designed for operating in rough industrial environments. However,the following mounting instructions should be observed in order to minimize mechanical, thermal andelectromagnetic influences on the operation.

4.1 General mounting instructions

The enclosure for wall mounting meets IP 65 and is designed for mounting the enclosure close to the sensorlocation. So, shorter shorter sensor cables can be used, which causes lower exposure to electromagneticnoise. This will lead to better measurement results.The control unit should be installed in locations where no vibration exists and no additional heat is transferredinto the system (even better reduce the heat in the control unit). In addition the control unit should be installedin such a fashion that it can be easily opened for service purposes. During operation, control unit and sensorsshould be under visual control of the operating persons.

Attention: Exposing the control unit to strong vibrations and additional heat can damage the unit.

For mounting the unit into switch panels or operator consoles, the front panel version should be used.


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4.2 Dimensions of the enclosure

Wall mount version (industrial enclosure)

80

205

192

180

125

140

80

Fixing holes for screws M4

Main plugSensor SwitchBox plug

RS232

ø20 ø26

Sensorplug

All dimensions are in mm.

Tolerance: ±0.2 mm

Picture: Dimensions of the wall mount enclosure - connection view


Rev. 1.0


Front panel versionFront view

Note: For connecting the cables, an installation space of min. 120mm depth mustbe provided (see illustration on next page).

ROLAND ELECTRONICMade in GermanyGerät Nr. Netz 24 VDC

D - 75210 KELTERN07236 - 9392-0

07236 - 9392-33TELEFONFAX

< Norm > Enable

ENTER MENUE

ROLAND R1000

10

10 170

Ø4.2

180

180

136

Front panel cutout(not true to scale)

All dimensions are in mm.

Tolerance: ±0.2 mm

Picture: Dimensions of the front panel version – front view


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Lateral view

425

131

105All dimensions are in mm.

Tolerance: ±0.2 mm

Picture: Dimension of the front panel version - lateral view


Rev. 1.0


4.3 Sensor mounting

71,5 50

All dimensions in mm.Length tolerances ± 0,8mm,all other tolerances ±0.2 mm

Picture: Dimensions of the sensor PW42AGS

The reliable function of the Double Sheet Detector depends to a great degree on the correct mounting ofthe sensors. The following mounting rules should be followed:

• The sensor must be mounted perpendicular to the sheet and contact fully the sheet surface. Foreignmatter should not obstruct the contact.

• Tilting or air gaps between the sensor and the sheet surface can result in faulty measurements.

• It is possible to cover the sensor surface with thin Teflon in order to avoid damage to the sheet metalsurface. However, this will reduce the performance and is thus not recommended.

• The sensor can be mounted in any direction, it can be installed above or below the sheet.

• The under-gauge threshold of the control unit must be correctly adjusted and the under-gauge signalat the 0-sheet output must be analyzed.

• The over-gauge threshold of the control unit must be correctly adjusted and the over-gauge signalat the 0-sheet output must be analyzed.

• It is recommended to mount the sensor in a spring loaded mounting bracket or directly into thevacuum cup (see the following sections).

Attention: Air gaps can result in faulty measured values. This applies also to tiltingor partial gaps or bowed sheets. Ignoring these factors can result in unreliableoperations.

The UDK20 can detect unintentional air gaps. The lower limit (LL) should be used for this purpose. LL shouldbe adjusted to more than 80 percent. An air gap causes a decrease of the measured value. As soon as themeasured value falls below the under gauge threshold, then under gauge is signaled at the 0-sheet output.It is absolutely necessary that the control unit stops the current operation and issue is a fault signal. Onlyif this fault condition is eliminated should sheet processing be allowed to continue.


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4.3.1 Spring loaded sensor bracket SHS42G-FB (with bellow suction cup)The spring loaded sensor bracket SHS42G-FB with bellow suction cup is intended for the installation ofthe PW sensor. It is well suitable for for use in robotic destackers, since transversal forces (appearingon fast turning motions) are well compensated.

The suction vacuum and the integrated nap ring assure a full-area pressure contact of sensor andsheet.The suction cup has a Shore hardness of 45 (red), suction cups with a Shore hardness of 60 (black)are available as spare part ( see chapter 12 „Order data - sensors and accessories).

On installing, attention must be paid that the sensor is thoroughly sealed (e.g. with Teflon tape) in thethread seating.

Considerations:

• The sensor face must align with the naps.

• The vacuum must adequately effect.

• The suction facility must be kept free from loading, i.e. the springs may only be low pre-tensioned.

• The suction facility must not be used as load-lifting device.

( 1 : 2 ) A-A ( 1 : 2 )

G 1

/2-

: unloaded 128±1

: unloaded 90±1

: Spring travel: appr. 37

enclosed = swingable angular connection

for hose: innerØ 6; outerØ 8

38

110

130

10x45,00°

70

50

Ø84,5

Ø21

39,5

33

15,0° M42x1,5

ISO 10642 - M

8x80-8.8

60,5

69,5

M42x1,5

20

65,5

A A

Ø10

2

Ø85

Ø99

1

2

3

1

2

3

Picture: Sensor holder SHS42G-FB


Rev. 1.0


4.3.2 Spring loaded sensor bracket SHS42GS (with flat suction cup)The spring loaded sensor bracket SHS42GS with flat suction cup is intended for accommodating the PWsensors. It is well suitable for for use in feeder destacking applications (only vertical motions, no turningmotions). For usage with robotic destackers the sensor bracket SHS42G-FB (with bellow suction cup) isto be preferred.

The flat shape of the sensor bracket assures rectangular contact with the sheet, due to low tilting moment.

The suction vacuum and the nap rubber (glued into the suction plate) assure a full-area pressure contactof sensor and sheet.

On installing, attention must be paid that the sensor is thoroughly sealed (e.g. with Teflon tape) in the threadseating.

Considerations:

• The sensor face must align with the naps.

• The vacuum must adequately effect.

• The suction facility must be kept free from loading, i.e. the springs may only be low pre-tensioned.

• The suction facility must not be used as load-lifting device.Teach-in and zero-adjust must be performed with built-in sensor. On retrofitting or removing a spring loadedsensor bracket the existing parameters can no longer be used. For each parameter set the teach-in mustbe newly performed.


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movable

Clamping bracket SHK

110

Spring loaded sensor bracket

Sensor

Cup

65

6

ø25

25

94

M8

40

Rubber nipples Sensor edge

Sensor

Suction cup

"A""A"

View in direction "A"without clamping bracket

ø20,5

40

90

30O

50

110

8045°

120°

75°

orcu

stom

mad

e30

0

Lift

max

.65

min

.25

98

5740

fixed

Connection forhose 12mminner diameter

Picture: Spring loaded sensor bracket SHS42GS with flat suction cup


Rev. 1.0


4.3.3 Spring loaded sensor bracket SH42GSFor utilization of PW sensors a spring suspended bracket is to be favourized instead of a rigid arrangement.A substantial advantage is in the fact that the sensor contacts the sheet perpendicularly, even thoughsensor bracket and sheet surface might not be completely aligned at a right angle.

Lateral pulling force on the sensor cable can be disadvantageous, since it might cancel-out the effect ofthe spring suspension. Furthermore, it must be ensured that the springs do not get stuck. If the springs getstuck, tilting of the sensor might no longer be compensated or tilting might even be provocated.

Ideally, the spring loaded bracket should be adjusted such that a slight pre-tension results. Thus the sensorface is perpendicular contacted to the sheet, even under dynamic conditions.

Considerations:

• A rigid sensor mounting bracket is unsuitable.

• Lateral pulling force on the sensor cable must be prevented by design and during operation.

• The travel of the springs should be dimensioned sufficiently and should not be fully used duringoperation. The sensor bracket should be mounted such that collision with other machine parts isexcluded, and does not result in the springs getting stuck.

• Assure enough spring pre-tensioning !

57

max

.65

min

.25

66

98

"A"Ø 10

Sensor

movable

fixed

"A"Ø 10

View in direction "A"

ø20,5

40

9030

O

50

110

8045°

120°

75°

lift

Picture: Spring loaded sensor bracket SH42GS


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4.3.4 Clamping device SHKThe clamping device SHK can be used for mounting the sensor brackets SHS42GS or SH42GS.

ø25

25

94

M20

M8

210

40

9,5

30

9,5

or c

usto

m m

ade

Picture: Clamping device SHK


Rev. 1.0


4.3.5 Incorrect installation of the PW sensorsThe following illustration shows examples of the incorrect installation of the PW sensors.

Faulty! The sensor does not touch the sheet.

Faulty! The sensor does not sitperpendicular on the sheet,sensor bracket apparently notsuitable.

Faulty! An air gap exists between first and second sheet. The sensor is mounted in an unfavorable position.

Faulty! An air gap exists between first and second sheet. The second sheet clings to the first sheet, perhaps by stamping residuals.

Faulty! Fault prone control in a bucket. An air gap exists between bended sheets.

Picture: Faulty mounting of PW sensors

4.3.6 Electromagnetic interferenceElectromagnetic interference can affect the measuring accuracy of the sensor. Therefore the sensorsshould not be installed close to devices which cause electromagnetic interference. Such devices are e.g.frequency converters, servo motors or proximity switches on inductive basis. In case of switching magnetsa minimum distance of 20 mm should be observed in order to avoid feedback.The sensor cables should not be placed directly adjacent to cables with large interference potential, e.g.power supply cables. This applies especially to longer cable lengths.


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4.4 Mounting of the Sensor Switch Box SSBUDK10

Note: The Sensor Switch Box SSBUDK10 should be installed in locations where novibration exists and no additional heat is transferred into the system (even betterreduce the heat in the control unit). Furthermore, the Sensor Switch Box must beinstalled such that it is always accessible and can be easily opened for servicepurposes. During the operation the Sensor Switch Box and the sensors should beunder visual control of the operating personnel.

Befestigungsbohrungen M4Holes for mounting screws M4

Alle Maße sind in mm. Maßtoleranz: 0,2 mm.All dimensions are in mm. Tolerance: ±0,2 mm.

±

250

238

52

8027

2559

95130

165200

230250

2740

55

Sen

sor

1

Sen

sor

2

Sen

sor

3

Sen

sor

4

Picture: Dimensions of sensor switch box SSBUDK10


Rev. 1.0


ROLAND

5. Electrical installation

5.1 General instructions

The control unit is connected to the associated machine via the central connection plug / socket. Thus theunit can be exchanged without unscrewing the cables.The central connection provides for supply voltage, inputs / outputs of the PLC and the central groundinglead of the associated machine.The cable shieldings of the PLC inputs / outputs are connected to the system grounding of the PLC onlyat one side of the cable.The sensor cables should be kept as short as possible in order to minimize interferences fromelectromagnetic fields. Cable shields must be connected according to the connection diagrams only andmust not have any additional connections.

Attention: Damaged cable installations can result in additional (unwanted) electricalconnections. This can distort the measured values.


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5.2 Allocation of connections

UDK20Unit in industrial housing

Unit as front plate mount

Picture: Connections R1000 UDK20

A Central connector (front plate mount: terminal strips for direct connection)B Connection for RS232 interfaceC Connection for sensor cableD Connection for sensor switch box


Rev. 1.0


ROLAND

UDK20-2PWUnit in industrial housing

Unit as front plate mount

Picture: Connections R1000 UDK20-2PW

A Central connector (front plate mount: terminal strips for direct connection)B Connection for RS232 interfaceC1 Connection for sensor 1C2 Connection for sensor 2


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5.2.1 Sensor connection - 1st sensorConnection of the 1st sensor to the control unit via the enclosed cable.

Picture: Sensor connection 1

nipelbacrosneS gninaeM eriwforuoloC tinulortnocta.onlanimreT

1NIP 1nI-W yerg 32

2NIP 2nI-W knip 42

3NIP CDV21+ der 91

4NIP CDV0 )elbacrosnesniteloiv/kcalb(kcalb 02

5NIP CDV21– eulb 22

6NIP 1enil-P mm1nworb 2 72

7NIP 1tuO-W nworb 52

8NIP 2enil-P mm1etihw 2 82

9NIP 2tuO-W neerg 62


Rev. 1.0


ROLAND

5.2.2 Sensor connection - 2nd sensorThe connection for the 2nd sensor is only present at unit versions UDK20-2PW-X-X-S-XX, but not at unitversions UDK20-X-X-S-XX.Connection of the sensor to the control unit via the enclosed cable.

Picture: Sensor connection 2

nipelbacrosneS gninaeM eriwforuoloC tinulortnocta.onlanimreT

1NIP 1nI-W yerg 34

2NIP 2nI-W knip 44

3NIP CDV21+ der 04

4NIP CDV0 )elbacrosnesniteloiv/kcalb(kcalb 14

5NIP CDV21– eulb 24

6NIP 1enil-P mm1nworb 2 74

7NIP 1tuO-W nworb 54

8NIP 2enil-P mm1etihw 2 84

9NIP 2tuO-W neerg 64


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5.2.3 Connection of Sensor Switch Box (SSB)The connection for the sensor switch box is only present at unit versions UDK20-X-X-S-XX, but not at unitversions UDK20-2PW-X-X-S-XX.Type of cable: SVCPWS-SSBUDK10

Picture: Connection of sensor switch box

nipelbacrosneS gninaeM ebrafnredA tinulortnocta.onlanimreT

1NIP 1langisrevo-hctiwS etihw 92

2NIP 2langisrevo-hctiwS neerg 03

3NIP langislortnoC nworb 13

4NIP CDV0 wolley 23

5NIP CDV42+ yerg 33

gnisuohgulP )dedis-htob(dleihselbaC

5.2.4 Connection of RS232The RS232 connection is installed in C version units only.

Pin 1 GND

Pin 3 TXD

Pin 4 RXD

Manufacturer / Types / Notes

RS232 Binder Type 768and others

Connection at the control unit

M8, 3 pinSocket contact (female) at the

control unit

Table: Pin configuration RS232

The interface cable SM8KRS232D9S belongs to the scope of supply.

2

3 1


Rev. 1.0


ROLAND

Cable SM8KRS232D9S:

2

1

2

3

4

5

GND - 1

RXD - 2

TXD - 3

5

3

2

6

7

8

9

1 3

shield connectionat cable receptacle

cable length 3 m

5.2.5 Central connection (central plug)The supply voltage as well as the PLC inputs / outputs are connected via the central plug.

Abb.: Central plug

5.2.5.1Machine groundingThe control unit must be connected to the central machine grounding by a cable with a cross-section ofat least 1,5mm2.

5.2.5.2Supply voltageThe connecting line for the supply voltage should be kept short. For cable length below 20m (65 ft) a cross-section of 2x1mm2 is sufficient, for longer lines the cross-section must be increased accordingly. For powerconsumption of the unit please see section „Technical data“.


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5.2.5.3Data inputs / outputs to PLC

Version R (relay outputs)

min. 12min. 12

2-sheet

1-sheet

0-sheet

Picture: Allocation of central plug UDK20 Version R (relay outputs)


Rev. 1.0


ROLAND

Allocation of central plug - version R (relay outputs)

02KDUgulplartneC–CLPstupniataD

CLP gulplartneC

noitcnuF .onniP tupnI noitacificepS

unemgnirusaeM0=noitceles


1A 0NI V03-31:HGIH,V8-0:WOL

tratsgnirusaeM 0tiB 2A 1NI V03-31:HGIH,V8-0:WOL

nI-hcaeT 1tiB 3A 2NI V03-31:HGIH,V8-0:WOL

tsujdaoreZ 2tiB 4A 3NI V03-31:HGIH,V8-0:WOL

– 3tiB 5A 4NI V03-31:HGIH,V8-0:WOL

tsetmetsyS 4tiB 6A 5NI V03-31:HGIH,V8-0:WOL



– 7tiB 8B 8NI V03-31:HGIH,V8-0:WOL

MOC/CLP – 9A nommoC CDV0

02KDUgulplartneC–CLPstuptuoataD

CLP gulplartneC

noitcnuF .onniP tuptuO noitacificepS

).k.otinu(evitcasiELBANEfidesolctcatnocyaleR*1C

2C0TUO0TUO

CAV052.xamA1.xam

detcetedsiteehs-2finepotcatnocyaleR*3C

4C1TUO1TUO

CAV052.xamA1.xam


6C2TUO2TUO

CAV052.xamA1.xam


8C3TUO3TUO

CAV052.xamA1.xam

--- 9C --- ---

detcennocyllanretniera7Cdna,5C,3C,1C.rN-niP*

02KDUgulplartneC–ylppusrewoplanretxEegatlovylppuS

ylppusrewoplanretxE gulplartneC

egatloV .onniP noitacificepS

CDV42 2B mm1.nim/V2–/V6+CDV42 2

CDV0 3B mm1.nim 2

gnidnuorgenihcamlartnec gnidnuorg mm5,1.nim 2

Table: Allocation of central plug UDK20 Version R (relay outputs)


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Version O (Opto-coupler outputs)

min. 12

min. 12

Picture: Allocation of central plug UDK20 Version O (opto-coupler outputs)


Rev. 1.0


ROLAND

Allocation of central plug - version O (opto-coupler outputs)

02KDUgulplartneC–CLPstupniataD

CLP gulplartneC

noitcnuF .onniP tupnI noitacificepS



1A 0NI V03-31:HGIH,V8-0:WOL

tratsgnirusaeM 0tiB 2A 1NI V03-31:HGIH,V8-0:WOL

nI-hcaeT 1tiB 3A 2NI V03-31:HGIH,V8-0:WOL

tsujdaoreZ 2tiB 4A 3NI V03-31:HGIH,V8-0:WOL


tsetmetsyS 4tiB 6A 5NI V03-31:HGIH,V8-0:WOL



– 7tiB 8B 8NI V03-31:HGIH,V8-0:WOL

MOC/CLP – 9A nommoC CDV0

02KDUgulplartneC–CLPstuptuoataD

CLP gulplartneC

noitcnuF .onniP tuptuO noitacificepS

siELBANEfiecnatsiser-wolswohsrelpuocotpO).k.otinu(evitca

*1C2C

0TUO+0TUO-

+-

siteehs-2fiecnatsiserhgihswohsrelpuocotpOdetceted

*3C4C

1TUO+1TUO-

+-


*5C6C

2TUO+2TUO-

+-


*7C8C

3TUO+3TUO-

+-

--- 9C --- ---

CDV002.xam;Am001.xamylsuounitnoc/Am051.xametulosba:tnerructuptuO

detcennocyllanretniera7Cdna,5C,3C,1C.rN-niP*

2KDUgulplartneC–ylppusrewoplanretxEegatlovylppuS

ylppusrewoplanretxE gulplartneC

egatloV .onniP noitacificepS

CDV42 2B mm1.nim/V2–/V6+CDV42 2

CDV0 3B mm1.nim 2

gnidnuorgenihcamlartnec gnidnuorG mm5,1.nim 2

Table: Allocation of central plug UDK20 Version R (relay outputs)


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5.2.6 Connection of the PW42GS sensor and the sensor cableFor the connection of the PW42AGS sensors the SCPWS-GG or SCPWS-GW can be used as in thefollowing picture.

Attention: The sensor cable is an active part of the sensor. The performance datais therefore based on the compliance with cable specification.

Picture: Connections of PW42GS sensor

Cable types for PW42AGS sensor (order data):

• SCPWS-GG (straight cable socket on sensor side)

• SCPWS-GW (90° angled cable socket on sensor side)All cables have a straight cable plug on the side of the control unit. The standard length is 5 meter, longercables up to 50 meters must be ordered.The sensor cables also serve as extension cables, without requiring separate “in-line quick disconnects“.

Note: Cables should not be laid-out close to other cables showing interferenceradiation (e.g. power cables), especially longer cables.


Rev. 1.0


ROLAND

5.2.7 Cable SVCPWS-SSBUDK10The cable SVCPWS-SSBUDK10 is used for connecting the control unit to the Sensor Switch Box.The following pin configuration and dimensions apply:

51 51

∅22

1 white2 green3 brown4 yellow5 grey Shield at plug enclosure

∅22

Cable receptacleCable plug

Receptacle contactPlug contact

To control unit To Sensor Switch Box

1 white2 green3 brown4 yellow5 grey Shield at plug enclosure

Picture: Connections and dimensions of the SVCPWS-SSBUDK10 cable

Note: For the connection of the SSBUDK10 to the sensor PW42AGS the SCPWS-GG or SCPWS-GW are used.


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5.3 Connection diagrams

This section covers the connection scheme for three typical applications of the R1000 UDK20 system.

5.3.1 UDK20-XX-S-XX with one PW42AGS sensor

Picture: Connection diagram with one PW42GS sensor


Rev. 1.0


ROLAND

5.3.2 UDK20XX-S-XX with SSBUDK10 and four PW42AGS sensors

Picture: Connection diagram with SSBUDK10 and four PW42AGS sensors


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5.3.3 UDK20-2PW-XX-S-XX with two PW42AGS sensors

Picture: Connection diagram with SSBUDK10 and four PW42GS sensors


Rev. 1.0


ROLAND

5.4 Internal wiring of the Sensor Switch Box SSBUDK10

X1X2

X3 X4 X5 X6

X7

X1, X3, X4, X5, X6 Meaning ColorPIN 1 W-in 1 greyPIN 2 W-in 2 pinkPIN 3 + 12 VDC redPIN 4 0 V DC black (black and violet in sensor cable)PIN 5 - 12 VDC bluePIN 6 P-lead 1 brown, 1 mmPIN 7 W-out 1 brownPIN 8 P-lead 2 white, PIN 9 W-out 2 green

2

1 mm2

X2 Meaning ColorPIN 1 Switching signal 1 whitePIN 2 2 greenPIN 3 Control signal brownPIN 4 0 VDC yellowPIN 5 +24 VDC grey

Switching signal

6 7 98 101 2 3 4 5

504947 48 55 5554535251

16 17 1918 2011 12 13 14 154641 42 43 44 45

26 27 2928 3021 22 23 24 25 36 37 3938 4031 32 33 34 35

gree

n

brow

n

gree

nw

hite

yello

w

grey

brow

n

blue

blac

kre

dpi

nkgr

ey

brow

n 12

whi

te 1

2

hite

12

brow

n 12

gree

n

blac

k

grey

pink red

brow

n

blue

whi

te 1

2

brow

n 12

gree

n

blac

k

grey

pink red

brow

n

blue

whi

te 1

2

brow

n 12

gree

n

blac

k

grey

pink red

brow

n

blue

hite

12

brow

n 12

gree

n

blac

k

grey

pink red

brow

n

blue

zu X1

zu X3 Zu X4

zu X5 zu X6

zu X2

Picture: Internal wiring of the Sensor Switch Box SSBUDK10


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Blank page


Rev. 1.0


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6. Communication with the PLC

The UDK20 has 9 potential-free, galvanically insulated (opto coupled) inputs. For the 4 outputs there arerelays or opto couplers available as alternatives.

6.1 External control

For external control parallel PLC inputs are available. If several functions are executed at the same time,then the unit issues a fault message. The following functions are possible:

- Measuring Start / Stop

- System test

- Selection of measuring programs

- Teach-in (not active by default)

- Zero adjust (not active by default)

Notes for the following diagrams and explanations:

For all the following diagrams and explanations, in the configuration menu item 11 „Level 0-1-2“ the setting„0V“ was selected.If „24V“ was selected, the outputs OUT1, OUT2 and OUT3 become inverted. Enable OUT0 will not beaffected by this.HIGH Level at the outputs means „relay contacts closed“ respectively „opto coupler low resistive“.LOW Level at the outputs means „relay contacts open“ respectively „opto coupler high resistive“.


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6.1.1 System testThe System test must be performed before each measuring cycle. During this test no sheet shouldbe in front of the sensor. This test serves for detecting the correct function of the unit. Simultaneouslyall outputs (also „Enable“) are activated for the duration of the system test. After the test all activated signalsare reset again.

System test

0-sheet

1-sheet

2-sheet

1 Check whether the output OUT0 „Enable“ has switched to HIGH (ready for operation),otherwise there is a fault condition.

2 Before initiating the system test, all inputs must be LOW for 30 milliseconds. No sheet must bein front of the sensor.

3 Switch the input IN5 „System test" to HIGH.4 All outputs have switched to LOW within 30 milliseconds.5 Switch the input IN5 „System test" to LOW.6 The unit now performs an internal system test. After a maximum time of 100 milliseconds all outputs

have switched to HIGH. If the configuration „measurement internal“ was selected, this check cannot beperformed since the unit starts the measurement cycle automatically. Therefore the mode„measurement external“ must be used.

Example:Check whether the output OUT0 „Enable“ has switched to HIGH 1. No sheet must be in front of the sensor. Allinputs must be LOW for more than 30 milliseconds 2.Now switch input IN5 to HIGH 3.After 30 milliseconds check whether all outputs have switched to LOW 4.Now switch input IN5 to LOW 5.After 100 milliseconds check whether all outputs have switched to HIGH 6.


Rev. 1.0


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6.1.2 Measurement menue selectionAll 255 measuring programs can be selected via the PLC inputs.For this the inputs IN0 to IN8 are used.

Attention: The inputs IN1-3 and IN5 are used also for functions other then theselection of the measuring programs. This means that the sequence in the timingdiagram has to be followed exactly.


2 Before selecting a measurement program, all inputs must be LOW for 30 milliseconds.3 Switch the input IN0 „Menu selection“ to HIGH.4 Simultaneously with 3 (or delayed) switch the binary values to IN1-8.5 Within 60 milliseconds after switching IN0 "Menu selection", the outputs OUT1-3 have switched to LOW.6 After the binary value has been present for a minimum of 60 milliseconds, switch the input

IN0 „Menu selection“ to LOW.7 Simultaneously with 6 (or delayed) switch back the binary value at IN1-8 (switch IN1-8 to LOW).8 After a maximum time of 180 / 480 / 240 milliseconds (depending on the material measured last and

the new type of material to be measured) all outputs OUT1-3 have switched to HIGH. If the configuration„Demo mode“ was selected, measurement will start automatically again (provided a valid program hasbeen selected). If the configuration „Measurement external“ was selected, the operation of the unit it isperformed via the PLC.

>= 0ms

min. 30ms max. 60ms

min. 60ms

>= 0

ms

max. 180ms for FE to FE, NE to NE or NE to FEmax. 480ms for FE to NE (for same sensor)max. 240ms for FE to NE (for different sensors / SSB)

Complete switching time max. 270 / 570 / 330 ms

(depending on the material measured

and the new material to be measured)

IN 0

OUT 0

IN 1-8

OUT 1,2,3

Menueselection

Enable

Bit 0-7

2-1-0-Sheet

1

2

3 4

5

6 7

8


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Example:1 Check whether the output OUT0 "Enable" has switched to HIGH.2 All inputs must be LOW for more than 30 milliseconds.3 Switch input IN0 „Menu selection“ and 4 simultaneously the binary value to IN1-8.5 Check after more than 60 milliseconds, whether the outputs OUT1-3 have switched to LOW.6 Switch the input IN0 7 and the binary value (IN1-8) to LOW.8 Wait the necessary time (refer to the diagram) until the outputs OUT1-3 have switched back to HIGH.

Note: Program no. Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

1 0 0 0 0 0 0 0 0

2 0 0 0 0 0 0 0 1

... ... ... ... ... ... ... ... ...

255 1 1 1 1 1 1 1 0

Not used 1 1 1 1 1 1 1 1


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6.1.3 Measurement Start / StopExternal control is different for single measurement and continuos measurement. If the sequencer modeis used, the signals 0-1-2-sheet will be formed as summary output (see „3.5 Applications examples“).

6.1.3.1Single measurementThe measurement result remains frozen until a new action is initiated.

*tS: The system reaction time is the time required by the unit in order to issue the result to the output after

the signal "Measurement Start" has been recognized (see sensor data for FE and NF material, chapter 2.2and 2.3).

Attention: In the relay output version the status of the outputs appears delayed (<10 ms),due to the switching time of the relays.

Note: High Level at the outputs means relay closed respectively opto coupler low resistant.Low Level at the outputs means relay open respectively opto coupler high resistant.

Note: Only for FE material (not for NF and LM): If several measurements are executedconsecutively, the measuring operation time should not exceed 10 seconds. It isadvisable to keep a recovery time of at least twice the measuring operation time.Example: 10 measurements within 1 second, then 2 seconds of recovering time. If therecovery time is less than twice the measuring time, the sensor will warm up and themeasuring value will drift.

min.30ms System reaction time tS*

min. 30ms

max.30ms

IN 0,2-8

OUT 3

OUT 2

OUT 1

Measurement Start

0-Sheet

1-Sheet

2-Sheet

EnableOUT 0

IN 1

1

2 3

4

5

6


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2 Before starting a measurement, all inputs must be LOW for 30 milliseconds.3 Switch the input IN1 „Measurement Start“ to HIGH.4 After 30 milliseconds the outputs OUT 1-3 have switched to HIGH for the duration of the measurement

(system reaction time see chapters 2.2 and 2.3 - depending on material and thickness).5 After point 4 or 30 milliseconds after point 3 switch the input IN1 „Measurement Start“ to LOW.6 The measurement result is available (after the system reaction time ts) at the outputs OUT1-3, it remains

frozen until the new action is initiated.

Example with „fast“ PLC/BUS cycle time (smaller 20 milliseconds):1 Check whether the output OUT0 „Enable“ has switched to HIGH.2 All inputs must be LOW for more then 30 milliseconds.3 After that switch input IN1 „Measurement Start“ to HIGH.4 Check whether all outputs OUT1-3 switch to HIGH within 30 milliseconds. 5 After that, switch input IN1

to LOW.6 Continue to interrogate the outputs OUT1-3, until (after system reaction time ts) the measurement result

is available.

Example with „slow“ PLC/BUS cycle time (larger 20 milliseconds):1 Check whether the output OUT0 „Enable“ has switched to HIGH.2 All inputs must be LOW for more then 30 milliseconds.3 After that, switch input IN1 „Measurement Start“ to HIGH.5 After more than 30 milliseconds switch input IN1 „Measurement Start“ to LOW.6 Continue to interrogate the outputs OUT1-3, until (after system reaction time ts) the measurement result

is available.


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6.1.3.2Continuous measurementThe control unit measures continuously as long as the signal “Measurement Start“ is switched to HIGH.If the signal “Measurement Start“ is switched to LOW, the measurement is aborted and the last measuringresult is frozen until a new cycle is initiated.

*tS: The system reaction time is the time required by the unit in order to issue the result to the output afterthe signal "Measurement Start" has been recognized (see sensor data for ferrous and non-ferrous material,chapter 2.2 and 2.3).*t

p: Additional recovery time of 0.5 seconds (for FE material)

Attention: In the relay output version the status of the outputs appears delayed(<10 ms) due to the switching time of the relays.

Note: High Level at the outputs means relay closed respectively opto coupler lowresistant. Low Level at the outputs means relay open respectively opto coupler highresistant.

IN 1

OUT 3

OUT 2

OUT 1

MeasurementStart

0-Sheet

1-Sheet

2-Sheet

Enable

tS *

min. 30ms

OUT 0

IN 2-8

min. 30ms tp + tS *1

2

3

4 5 6

7

max. 30ms


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2 Before starting measurement, all inputs must be switched to LOW for 30 milliseconds.3 Switch the input IN1 „Measurement Start“ to HIGH.4 Within 30 milliseconds, the outputs OUT 1-3 have switched to HIGH for the duration of the measurement

(system reaction time see chapter 2.2 and chapter 2.3 - depending on material and thickness).5 The measurement result is available after the systems reaction time ts at the outputs OUT1-3. The

measurement starts again. An additional recovering time of 0.5 seconds is awaitet (for FE material).6 The measurement result of the 2nd measurement is available at the outputs. The measurement

starts again.7 Switch the input IN1 „Measurement Start“ to LOW. The measurement is aborted, the last measurement

result is now available at the outputs OUT1-3. The measurement result is frozen until a new cycleis initiated.

Example with „fast“ PLC/BUS cycle time (smaller 20 milliseconds):1 Check whether the output OUT0 „Enable“ has switched to HIGH.2 All inputs must be LOW for more then 30 milliseconds. 3 Then switch input IN1 „Measurement Start“

to HIGH.4 Check whether all outputs OUT1-3 switch to HIGH within 30 milliseconds. 5 Continue to interrogate

the outputs OUT1-3, until (after the systems reaction time ts) the measurement result is available.6 If required, interrogate several measurements.7 Then switch input IN1 to LOW. The measurement is aborted, the last measurement result is now

available at the outputs OUT1-3. The measurement result is frozen until a new cycle is initiated.

Example with „slow“ PLC/BUS cycle time (larger 20 milliseconds):1 Check whether the output OUT0 „Enable“ has switched to HIGH.2 All inputs must be LOW for more then 30 milliseconds. 3 Then switch input IN1 „Measurement Start“

to HIGH.5 Continue to interrogate the outputs OUT1-3 until (after the systems reaction time ts) the measurement

result is available.6 If required interrogate several measurements.7 Then switch input IN1 to LOW. The measurement is aborted, the last measurement result is now

available at the outputs OUT1-3. The measurement result is frozen until a new cycle is initiated.


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6.1.4 External zero adjust (via PLC inputs)This function may be required for special applications. It is, however, switched off in the standard factoryadjustment. If required it can be activated according chapter “7. Start-up“.

Note: During Zero adjust no sheet must be in front of the sensor.


2 Before initiating zero adjust all inputs must be LOW for 30 milliseconds. No sheet must be in frontof the sensor.

3 Switch the input IN3 „Zero adjust“ to HIGH.4 Within 30 milliseconds the outputs OUT1-3 have switched to LOW.5 After point 4 or 30 milliseconds after point 3 switch the input IN3 „Zero adjust“ to LOW.6 Now the unit performs a zero adjust. The zero adjust is completed within 15s and the outputs OUT1-3

switch to HIGH.

Example:1 Check whether the output OUT0 „Enable“ has switched to HIGH.2 No sheet must be in front of the sensor. All inputs must be LOW for more than 30 milliseconds.3 Now switch input IN3 to HIGH.4 After 30 milliseconds check whether outputs 1-3 have switched to LOW.5 Now switch input IN3 to LOW.

6 After >15 seconds check whether the outputs 1-3 have switched to HIGH.

IN 3

OUT 3

OUT 2

OUT 1

Zero adjust

0-Sheet

1-Sheet

2-Sheet

Enable

max.30ms

1 sensor 8s2 sensors 15s

IN 0-2,4-8

OUT 0

min.30ms

min.30ms

1

2

3

4

5

6


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6.1.5 External Teach-in (via PLC inputs)This function is required only for special applications and is not available as default. If required, it can beactivated according to chapter “7. Start-up“.

Note: During Teach-In one sheet of nominal thickness must be placed in front of thesensor.

Attention: A zero adjust procedure has to be executed immediately before theTeach-in procedure.


2 Before initiating the Teach-In, all inputs must be LOW for 30 milliseconds. One sheet of nominal thicknessmust be placed in front of the sensor.

3 Switch the input IN2 „Teach-In“ to HIGH.4 Within 30 milliseconds the outputs OUT1-3 have switched to LOW.5 After point 4 or 30 milliseconds after point 3 switch the input IN2 „Teach-In“ to LOW.6 Now the unit performs a „Teach-In“ procedure, which is completed within 7s. Then the outputs OUT1-3

switch to HIGH.

Example:1 Check whether the output OUT0 „Enable“ has switched to HIGH.2 One sheet must be in front of the sensor. All inputs must be LOW for more than 30 milliseconds.3 Switch input IN2 to HIGH. 4 After 30 milliseconds check whether outputs 1-3 have switched to LOW.5 Switch input IN2 „Teach-In“ to LOW.6 After >7 seconds check whether the outputs OUT1-3 have switched to HIGH.

IN 2

OUT 3

OUT 2

OUT 1

IN 0,1,3-8

OUT 0

Teach-In

0-Sheet

1-Sheet

2-Sheet

Enable

max.30ms

max. 7 sec.

min.30ms

min.30ms

1

2

3

4

5

6


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6.1.6 Typical measuring cycle when using the unit for destacking

In order to ensure reliable functioning of the system, the following operating cycle is recommended.It is recommended to perform step 2 at each cycle.

1. Selection of the desired measuring program.2. System test without a sheet in front of the sensor (this test must be performed).

- checking the outputs. All outputs are switched LOW while the system test is performed.- internal test: unit and sensor will be checked for function, no sheet must be in front of the sensor.

3. The sensor is lowered onto the stack (which contains 1 or more sheets).4. Detection of the last sheet in the stack (1-sheet signal = only one sheet in the stack).

Condition: no metal underneath the last sheet.5. Destack a sheet and move into monitoring position - at least 2 cm (.8 inch) away from stack.6. Monitor and intitiate action depending on measurement result:

- 0-sheet: Repeat destacking operation.- 2-sheet: Initiate actions to remove double sheet or several sheets from destacker.Has the measure been executed, measure again.Attention: During the removal operation, the measuring function should be switched off becauseof potentially undefined conditions, air gaps between sensor and sheet etc.- 1-sheet: continue with item 7.

7. Transport sheet into the proper loading position.8. Measure to verify that the sensor is still on the sheet.9. Deposite the sheet.10. After de-stacking a sheet perform security check to verify that the sheet is de-stacked.11. Before de-stacking a new sheet perform item 1 “Selection of the desired measuring program“

or item 2 “System test“, without a sheet being in front of the sensor.


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7. Start-up

7.1 Initial Start-up

The R1000 UDK20 is designed for an operating voltage of 24 VDC (+6V / –2V). This voltage should bechecked before applying power. The control unit is automatically switched on by the application of power.After applying power, the type of the system, the version number and the bus system message are brieflydisplayed. Afterwards the system switches into the measurement menu, which was active before the unitwas switched off. If the equipment does not power up, the fuse should be checked.

Attention: The checking of the fuse should be made by trained personnel only,because it is necessary to open the control unit.

Fuse for the supplied voltage: 3,15 Amp slow blow, 5 x 20 mm.A spare fuse is stored in the control unit, the position of the spare fuse is shown in the following picture.

Note: The picture shows a control unit for front panel mounting. The position of thefuse is identical in the wall mount enclosure.

Picture: Position of the fuses in the R1000


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7.2 Operation

Note: The system is factory adjusted for “external single measurement“. Thereforethe system functions only if the signal “measurement start“ is activated. Themodification of the configuration is described in the following sections.

After applying power the type of the system, the version number and the bus system message are brieflydisplayed. Afterwards the system switches into the measurement menu, which was active before the unitwas switched off.

1-1 FE=1.00 -ON80% <S1=1.02> 120%

1-1 FE=1.00 -ON80% <S1=1.02> 120%

Upper limitMeasuring valueSensor no.Lower limit

Program numberSelected sensor (1-4)MaterialNominal thicknessMeasurement active

LED keys

Picture: Frontal view of the R1000 with increased display cutout

Functions of the keys (symbols below the keys)↑ : Change the parameters (forward)↓ : Change the parameters (backwards)Enter : Selection of a parameter for the change and confirmation of the changeMenü : Activation of the menu level, for deleting a fault message and leave the menu level.

Functions of the LEDs (symbols above the keys)< : ON, if the measured value equals or is below the lower limit value TU or falls below.Norm : ON, if the measured value within the limits TU and TO lies.> : ON, if the measured value reaches or exceeds the upper limit value TO.Enable : - blinks, if a fault occurred

- ON, if the equipment is in the measurement mode- OFF, during parameter programming with the keyboard


Rev. 1.0


7.3 Configuration menu

1 Language German / English / Spanish Italian / French2 Sensor type PW42A

3 Number of sensors 1, 2, 3, 4 sensors (at SSB 1-4; at 2PW 1,2)

4 Dimensionn mm / inch

5 Measuring mode Demo mode / external single measurement / external continuous measurement

fast / normal

7 FE - T-Limit 66/125% / 33/142%

8 CLR Parameter (Clear Program Parameter) off / on

9 Password yes / no

10 External adjust yes / no

11 Level 0-1-2 output 0V DC / +24V DC

12 Diagnosis factor Conductivity / nominal value / Teach factor

13 W-Diagnosis Conductivity range / thickness range / thickness with AD value / frequency + gain

UDK20-PR-S-(X)SV:xx HV:xx

14 Version (factory setting, do not change !)

1 Program no. (1-255)

2 Sensor number 1,2, 1+2 (only 2PW) 1-4 (only SSB)

3 Material Auto / NF / FE / LM (slightly magn. NF)

4 Nominal thickness (0,03 - 4mm) (0.001 - 0.157 inch)

5 TO% (100 - 150%) and absolute (TO = UL upper limit)

6 TU% (0 - 99%) and absolute (TU = LL lower limit)

7 Zero adjust off / all / separate

8 Teach-In ok / missing / on / without

System Parameters

Configuration

Program Parameters Data backup(only for C-versions)

FirmwareUpdate

Modefor

Data backup

Mode forFirmwareUpdate

Password

changeview

Configuration

Menu key

Picture: Structure of the configuration menu


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7.4 General information regarding configuration

Note: The correct configuration depends on the communication with the PLC, onthe measurement task and the attached components.

The following rules apply to the operation in the configuration mode:

• The configuration mode is activated (while in measurement mode) by pressing the MENU key.

• The configuration mode is completed or aborted by pressing the MENU key.

• The selection of parameters or the adjustment of parameters can be changed if these items blink inthe display.

• The selection of parameters or parameter adjustment is activated by pressing the ENTER key.

7.5 Changing, adjusting or checking the configuration

In order to select, change or check the system and program parameters, push the MENU key.

The following menu item appears:

Configurationreview

Picture: Display of selected menu

This menu option allows the selection between configuration review and configuration change.

Configuration review: The system and program parameters cannot be changed. The measurementmode is not interrupted.

Configuration change: All system and program parameter can be changed after entering the password.

The following menu item appears.

Password4711

Picture: Entering the password

Every blinking digit can be changed with the arrow keys and confirmed with the ENTER key. After the correctpassword has been entered, the following menu appears for the adjustment of the configuration mode. Ifthe entered password is incorrect then the cursor returns to the first digit of the password and the input mustbe repeated. The input of the password can be aborted by pressing the MENU button.

Note: A fault is generated if PLC commands are executed while entering the password or changingparameters.

Configurationprogram param.

Picture: Adjusting the configuration mode


Rev. 1.0


Available configuration modes:

• Configuration system parameter

• Configuration program parameter

• Data backup (not for B version units)System parameters are general adjustments (e.g. language).Program parameters are specific adjustments, depending on the application (e.g. input of nominalthickness).

Note: After leaving the configuration mode the password remains active for fiveminutes. Thus other configuration adjustments can be made, without re-entering thepassword. If no keys are pressed while in the menu level than the program changesinto the measurement mode.

7.6 System parameters

Note: The selected system configuration should be documented in the form“System configuration“ in chapter 11.“Technical data“ or in the equipmentdocumentation. This information is required in case a system becomes exchanged.

The general adjustments are specified by the configuration of system parameters.For this purpose the system parameter configuration mode must be selected and confirmed with ENTER.

Then the following menu item appears:

System parameter 1: setting the dialog language.

System param.: 1language:english

Picture: Seltting the dialog language

System parameter 2: specifying the type of sensor.

System param.: 2sensor type:PW42

Picture: Specifying the type of sensor

Note: Currently only the type of sensor PW42A is selectable.


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System parameter 3: specifying the number of sensors connected.Selection for 2PW units: 1/2 sensors; selection for SSB: 1, 2, 3, 4 sensors.

Attention: If a particular configuration is changed, all stored program parameters aredeleted. Then for all types of material the nominal thicknesses must be enteredagain and the teach-in executed.

System param.: 3number sensors:2

Picture: Setting the number of sensors

System parameter 4: specifying the dimensions (mm / inch).If the measurement dimensions are changed, then the sheet metal thicknesses of the stored programsparameter are converted into the new dimension.

System param.: 4dimension: mm

Picture: Setting the dimension for the display

System parameter 5: setting the measuring mode.

System param.: 5mode: ext.cont.

Picture: Setting the measuring mode

The following measuring modes are possible:

• External continuous measurement: The system executes measurements, as long as the“Measurement start“ signal is applied via the external PLC input. For FE material the repetition timeof the measurement is 0.5 seconds; for NF and LM it is less than 0.085 seconds.

• External single measuring: The system measures once if the “Measurement start“ signal is appliedvia the external PLC input. Each measurement must initiated separately. The hints in chapter 6.1.3.1„timing diagram single measurement“ must be abided by.

• Demo mode: This mode of operation is intended for equipment demonstrations but not for the normalprocess operation. The system executes measurements continuously. For FE material the repetitiontime of the measurement is 1 second; for NF and LM it is less than 0.085 seconds.


Rev. 1.0


System parameter 6: specifying the mode for FE measuring.

System param.: 6measurement:fast

Picture: Mode for FE measuring

This setting influences only the FE measurement (magnetic steel).

Possible adjustments:

• FE Measurement normal: With this kind of measuring the system reaction time depends on themeasured sheet thickness. The maximum can be inferred from the diagrams in the chapter2.2 "Sensor data“.

• FE Measurement fast: Here the system can detect whether double sheet metal is in front of thesensor before the "normal" end of the measurement. The system reaction time is shorter, dependingon the adjusted nominal thickness as well as the upper limit value.

Disadvantage: In case of measuring results larger than the double sheet threshold, a double sheetsignal is issued instead of the actually measured values.

For NF and LM (slightly magnetic NF) the exact measuring value is always output.

System Parameter 7: specifying the teach-in limits for FE.

System param.: 7T-limit:66%/125%

Picture: Specifying the teach-in limits for FE

Possible settings: 66% / 125% (default setting)33% / 142%

During teach-in of FE material the deviation of the measured thickness from the nominal thickness ismonitored. Certain ferro-magnetic materials show a larger deviation than usual. In those cases the33%/142% setting instead of the default 66%/125% setting is useful. Both values represent the thepermitted relative range from measured to nominal thickness. If the measuring value is not within thisrange, the teach-in cannot be performed and will be aborted with an error message.

System parameter 8: deleting all measuring programs.

Attention: This action cannot be undone.

System param.: 8CLR param.: no

Picture: Deleting the measuring programs


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System parameter 9: switching the password on / off.

System param.: 9password: yes

Picture: Switching the password on / off

Attention: If the password protection is de-activated, then all parameters can beaccessed at any time. This is recommended only for starting-up the system. Fornormal operation the password protection should be activated.

System parameter 10: deactivating the external calibration.Here the external calibration can be deactivated, which is possible via the interface with the signals“Teach-in 0-sheet“ and “Teach-in 1-sheet“.

System param.:10ext. adjust: no

Picture: Activate / deactivate the external calibration

System parameter 11: setting the logic of the 0-sheet, 1-sheet and 2-sheet outputs.

System param.:11output 0-1-2: 0V

Picture: Adjustment of the logic of the 0-sheet, 1-sheet and 2-sheet outputs

Possible settings:

• 0 V: As depicted in the timing diagrams and the wiring diagrams

• +24 V: The outputs 0-, 1- and 2-sheet are inverted, i.e. the respective signals in the timing diagramsand wiring diagrams must be inverted.

Attention: The output ENABLE is not affected thereby.

System parameter 12: equipment diagnostics (Teach-in factors).These parameters should not be changed by the user.

System param.:12diagnos. factors

Picture: Fixed systems parameter diagnostics


Rev. 1.0


The ENTER key leads to the following menu item:

System param.:12P12 LW:24-32mS/m

Picture: Indicating the investigated conductance

Here the conductivity investigated for this program is shown (here: prog. 12)

Extra: = slightly magnetical NF material

FE = magnetical steel

For NF material the conductivity range is shown.With the ENTER key and UP/ DOWN keys all programs can be polled / indicated.The ENTER key will exit the section.

The UP key leads to the following menu item:

System param.:12P12 N=2.12mm

Picture: Indicating the nominal thickness for the program

Here the nominal thickness for this program is shown (here: prog. 12).With the ENTER key and UP/ DOWN keys all programs can be polled / indicated.The ENTER key will exit the section.


System param.:12P12 FKT=1.112

Picture: Indicating the factor for the program, investigated on teach-in

Here the factor (2PW units: both factors) for this program, investigated on teach-in, is shown (here: prog.12).With the ENTER key and UP/ DOWN keys all programs can be polled / indicated.The ENTER key will exit the section.


System param.:12P12 EXIT

Picture: Exiting the factor diagnosis section

The ENTER key will exit the factor diagnostics.


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System parameter 13: equipment diagnostics (W-diagnosis)

System param.:13W-diagnostics

Picture: Fixed systems parameter diagnostics

Note: The settings of the current program will be taken over as default settings.

The ENTER key leads to the following menu item:

System param.:13LW: 24-32mS/m

Picture: Setting the conductivity range for the dignosis

Here the conductivity range for the diagnosis is set.Extra: = slightly magnetical NF materialFE = magnetical steel

For NF material the conductivity range is shown.

With the ENTER key and UP/ DOWN keys all ranges can be selected.The ENTER key will exit the section.


System param.:13DB: <4.00mm

Picture: Setting the thickness range for the diagnosis

Here the thickness range for the diagnosis is set.With the ENTER key and UP/ DOWN keys all ranges can be selected.The ENTER key will exit the section.


System param.:13AD:2048 D:1.22mm

Picture: Indicating the thickness calculated from the characteristic curve

Here the value of the analog-digital converter and the thickness (calculated from the characteristic curve)are shown (without teach-in correction). For 2PW units the values for both sensors will be shown.


System param.:13F=250Hz V=157

Picture: Indicating the frequency and gain

Here the used frequency and gain is shown.


Rev. 1.0



System param.:13Sensor demagnet.

Picture: De-magnetizing the sensor

Here the sensor will be de-magnetized.


System param.:13 EXIT

Picture: Exiting the factor diagnosis section

The ENTER key will exit the factor diagnosis section.

Indication of Type of unit, Software version, Hardware versionHere the type of unit, the Software version and the Hardware version will be shown. This indication can alsobe called up with the ENTER key in the main menu.

UDK20-2PW-B-O(2)SV: 002 HV: 001

Picture: Indicating the type of unit, software version, hardware version

Code:UDK20 = type of unit2PW = version 2PWB-O = version of unit(2) = 2 sensors connectedSV = software versionHV = hardware version

System parameter 14: indicating the system version.

System param.:14VERSION: BO

Picture: Indicating the system version

Note: This factory setting must not be changed !


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7.7 Program parameters

The program parameter contain the necessary information required for the various measurement programs.Select the mode “configuration program parameter“ and confirm with enter.

Program parameter 1: selecting the measuring program.

System Param.:12P12 LW:24-32mS/mProgram Par.: 1program number:1

Picture: Selecting the measuring program

Here the measuring program (1-255) is selected, for which the parameters are to be adjusted. All of thefollowing adjustments apply to the selected program number (here: program no. 1).

Program parameter 2: selecting the sensor (1/2 for 2PW, 1-4 for SSB) to be used for measuring.

System Param.:12P12 LW:24-32mS/mProgram Par.: 2sensor no.: 1

Picture: Selecting the sensor

If the number of sensors was set to “1 sensor“ in system parameter 11, then this parameter will not appear.Possible settings:

• 2PW unit: 1, 2, 1+2

• Unit with SSB: 1, 2, 3, 4

Program parameter 3: adjusting the material of the sheet to be measured.

System Param.:12P12 LW:24-32mS/mProgram Par.: 3material: auto

Picture: Adjusting the material

Possible settings:

• Auto: During teach-in the system determines by itself the type of material in front of the sensor.

• NF (non-ferrous): Non magnetic material, e.g. aluminium, autenitic stainless steel

• FE (ferrous): Magnetic material

• mag. NF (LM): low magnetic material


Rev. 1.0


Program parameter 4: entering the nominal thickness of the sheet to be measured.

(Nominal thickness is normally the sheet thickness used for teach-in.)

Attention: A change of the nominal thickness deletes the values determined duringTeach-in. A new teach-in is necessary.

System Param.:12P12 LW:24-32mS/mProgram Par.: 4nom.thick.:0.90mm

Picture: Setting the nominal thickness

Possible values:

• 0.03 mm to 4 mm (.001 inch to 0.157 inch).

Program parameter 5: setting the percentage threshold of the upper limit.

System Param.:12P12 LW:24-32mS/mProgram Par.: 5up:150% 1.350mm

Picture: Setting the upper limit

Possible values:

• 100% to 150%. At the same time the absolute limit value is displayed.

Program parameter 6: setting the percentage threshold of the lower limit.

System Param.:12P12 LW:24-32mS/mProgram Par.: 6low:50% 0.450mm

Picture: Setting the lower limit

Possible values:

• 0% to 99%. At the same time the absolute limit value is displayed.


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7.7.1 Program parameter 7: Zero adjust

System Param.:12P12 LW:24-32mS/mProgram Par.: 7zero adjust: off

Picture: Status of zero adjust

Zero adjust is initiated with the ENTER key. If no zero adjust was executed or if it has to be repeated, themenu option “on“ has to be selected.

Then the following message appears (with version 2PW only):

• Separate: All connected sensors must be zero adjusted individually, each sensor is addressedindividually for yes or no.

• Common: All sensors are zero adjusted at the same time.

In any case the zero adjust continues with the following message, requesting to remove the sheet:

System Param.:12P12 LW:24-32mS/mProgram Par.: 7 remove sheet !

Picture: Removing sheet for zero adjust

After having the sheet removed, press the ENTER key. Then the following message appears during the zeroadjust:

System Param.:12P12 LW:24-32mS/mProgram Par.: 7 please wait

Picture: Display during zero adjust

Note: Fault messages messages are described in the chapter 9.3 “Zero adjust fault“.

When the zero adjust is completed, the following message appears:

System Param.:12P12 LW:24-32mS/mProgram Par.: 7zero adjust:done

Picture: Zero adjust successfully completed

The zero adjust is now completed.


Rev. 1.0


7.7.2 Program parameter 8: Teach-in

System Param.:12P12 LW:24-32mS/mProgram Par.: 8teach-in: ok

Picture: Status of Teach-in

Possible teach-in items:

• Missing: A teach-in has not been executed (only for NF)

• Without: There is no teach-in existing, unit can be operated anyhow (only for FE)

• OK: A teach-in was already executed

• On: Performs a teach-in

Note: In order to enable measuring with a particular parameter set, a teach-in musthave been executed.

If no teach-in was executed or if a teach-in has to be repeated, the menu option “on“ has to be selected.Then the following two messages appears in succession:

System Param.:12P12 LW:24-32mS/mProgram Par.: 8 remove sheet !

Picture: Request to remove sheet for teach-in

System Param.:12P12 LW:24-32mS/mProgram Par.: 8 attach sheet !

Picture: Request to attach sheet for teach-in

Now a sheet with the nominal thickness must be presented to the sensor.

Attention: The sheet must contact the sensor without air gap. The position of thesheet during teach-in must be identical to the position during normal operation.Otherwise the measurement result could be faulty.

Then press the ENTER key.During the teach-in procedure the following message is displayed:

System Param.:12P12 LW:24-32mS/mProgram Par.: 8 please wait

Picture: Display during the teach-in for one sheet

Note: Fault messages are described in chapter 9.4 “Teach-in faults".


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Then the following message appears:

System Param.:12P12 LW:24-32mS/mProgram Par.: 8TI-value: 0.97mm

Picture: Teach-in measurement value

This measured value can be accepted or changed, for example to calibrate the control unit.

After the teach-in has been completed the following message appears:

System Param.:12P12 LW:24-32mS/mProgram Par.: 8teach-in: ok

Picture: Teach-in successfully completed

Attention!For sequence 1+2 the teach-in is separately performed for sensor 1 and 2.

Entering the information for the selected measuring program is now completed.


Rev. 1.0


Description of the Teach-In procedure

local at unit via PLC (parallel)

For material (system parameter 2) FE NF / LM FE NF / LM

Step 1: attach sheet and initiate Teach-In

Measured thickness will be displayed.

Characteristic curve will be determined. Nominal value will be displayed.

Measured thickness will automatically

corrected to nominal value.

Measured thickness will automatically

corrected to nominal value.

Correct measured thickness to nominal value (e.g. measured with micrometer screw).

Correct measured thickness to nominal value (e.g. measured with micrometer screw).

Step 2: Calibration

Maximal possible correction see I.

Correction ± 20% of nominal value.

Maximal corrected deviation see II.

Deviation will be internally corrected.

I: depending on the set T-limit (system parameter)a: 66% / 125%:

- possible upward correction of the displayed thickness: max. 150 % of the indicated value but not more than 125 % of the set nominal thickness, but not more than the max. measurable thickness (depending on sensor; 4mm for PW42AGS)- possible downward correction of the displayed thickness: min. 80% of the indicated value but not less than 66 % of the set nominal thickness

b: 33% / 142%:- possible upward correction of the displayed thickness: max. 300 % of the indicated value but not more than 142 % of the set nominal thickness, but not more than the max. measurable thickness (depending on sensor; 4mm for PW42AGS)- possible downward correction of the displayed thickness: min. 70% of the indicated value but not less than 33 % of the set nominal thickness

II: depending on the set T-limit (system parameter)a: 66% / 125%:

- the ratio of measured to nominal value must be between 66% and 125%b: 33% / 142%:

- the ratio of measured to nominal value must be between 33% and 142%

Attention! For operation with „sequence 1+2“ the values for sensor 1 and 2may not deviate from each other for more than ± 20 %.


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7.8 Data backup via serial RS232-interface (only for C-versions)

For better prevention against data loss, a data backup procedure is available for the system configurationand the parameter sets. This is performed via the RS232-interface (only for C- versions). The secured datacan be tranfered to spare units in case of exchange after a failure.The data backup is accomplished with the RPP-XP software available from ROLAND (for Win2k, WinXP).The procedure can be selected in the menu configuration. The following menu is displayed during the databackup.

System Param.:12P12 LW:24-32mS/mParameter backup active

Picture: Back-up of the data via RS232 interface


Rev. 1.0


8. Operation

8.1 Abbreviated operating instructions

After applying power the type of the system, the version number and the bus system message are brieflydisplayed. Afterwards the system switches into that measurement menu, which was active before the unitwas switched off.

Note: The system is factory adjusted for “external single measurement“. Thereforethe system functions only if the signal “measurement start“ is activated via the PLCinput. The modification of the configuration is described in chapter 7. “Start-up“.

1-1 FE=1.00 -ON80% <S1=1.02> 120%

1-1 FE=1.00 -ON80% <S1=1.02> 120%

Upper limit valueMeasuring valueSensor no.Lower limit value

Program numberSelected sensor (1-4)MaterialNominal thicknessMeasuring is active

LED keys

Key functions

LED functions

Picture: Frontal view of the R1000 with increased display cutout

Functions of the keys (symbols are below the keys)↑ : Change the parameters (forward)↓ : Change the parameters (backwards)Enter : Selection of a parameter for the change and confirmation of the changeMenü : Activation of the menu level, for deleting a fault message and leave the menu level.

Functions of the LEDs (symbols the above the keys)< : ON, if the measured value equals or is below the lower limit value TU or falls below.Norm : ON, if the measured value within the limits TU and TO lies.> : ON, if the measured value reaches or exceeds the upper limit value TO.Enable : - blinks, if a fault occurred

- ON, if the equipment is in the measurement mode- OFF, during parameter programming with the keyboard


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In the measuring mode, the measured value is shown on the display. The comparison of the measured valuewith the adjusted thresholds is done automatically by the control unit.The result is transmitted via theinterface to the PLC and also to the front panel LED's.During the normal measurement process no further actions on the control units are necessary with thefollowing few exceptions. The following situations require action directly at the control unit:

• Clear fault and error messages (see to chapter 9. “Fault messages, causes and remedies“)

• Teaching of new types of metal and sheet metal thicknesses(see section 7.7 “Configuration of program parameters“)

• Clearing a 2-sheet condition (in preparation)

The following notes for measuring operations should be observed:

Note: If the measured value fluctuates and deviates substantially from nominalvalue during normal operation then an air gap between sensor and sheet surface isthe most likely cause. A renewed Teach-In cannot solve this problem.

Note: With non-ferrous materials (e.g. aluminum) changes in the electrical conductivitycan occur requiring a teach-in.

Note: Do not adjust the upper threshold above 120 %.


Rev. 1.0


8.2 Entering a new measurement program

1 Make sure that there is no sheet in front of the sensor

2 Press them menu key and move to “change“, confirm with ENTER key

3 Enter the password

4 Move to "program parameter" and confirm with ENTER key

5 Make sure that there is no sheet in front of the sensor

6 Select the desired program number in the control unit

7 If sensor a Sensor Switch Box is installed select the desired sensor

8 For the type of material select “auto“

9 Enter nominal thickness (standard thickness of the sheet to be processed)

10 Set lower threshold TU to 80% set (default settings)

11 Set upper threshold TO to 120% set (default settings)

12 Ensure that no sheet is in front of the sensor

13 Select "teach-in" and move to “on“, confirm with ENTER key

14 Remove sheet in front of the sensor, confirm with ENTER key

15 If the control unit signals “attach sheet to sensor“, operate machinery to accomplish this. Ensure thatthere is no air gap between sensor and sheet metal surface. Confirm with ENTER key.

Attention: The sheet used for the teaching process must have the same sheetthickness and same electrical conductivity (in case of non- magnetic metal e.g.aluminum) as the sheet to be processed.

16 The control unit shows the measured thickness in the display.

General rules for monitoring ferrous material (steel that can be magnetized) and non-ferrous materials(aluminum, non-magnetic stainless steel, slightly magnetic non-ferrous material):

– Ferrous material: The measured value should not deviate by more then 5%, (max. 10% with coatedsheets, exceeding 10% with nickel) from the actual thickness of the measured sheet. If it deviatesmore, then the cause could be a wrong sheet thickness or an air gap, which has to be eliminated(do not use bowed sheet for teaching). The measured value must now be adjusted to the actualsheet thickness.

– Non-ferrous material and slightly magnetic material: The measured value must be adjusted to theactual sheet thickness

17 Confirm the teach-in and adjustment with the ENTER key and exit the menu “programming“.

Example: Nominal thickness 2.00 mm

The micrometer measures actual value to be: 1.92 mm.

The teach-In shows a value of: 1.89 mm.

The display value must now be corrected to 1.92 mm.


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Rev. 1.0


9. Fault messages, causes and remedies

In case of a fault, the control unit displays an error message, showing error number and error class of themalfunction.

System Param.:12P12 LW:24-32mS/mError code: 60 power

Picture: Example of a fault message

The fault number indicates the fault and the probable cause. The description of the fault and the suitableremedy are found in the the following tables. Before the equipment can continue operation, the cause ofmalfunction must have been redressed and then confirmed (MENU key).

Note: If the cause of the fault is not redressed, then the fault cannot be cleared.

The fault messages are summarized into the following classes:

• Memory fault

• Teach-in faults

• Transmission faults (RS232)

• Measuring operating faults

• Keyboard faults

• Operating voltage faults

• Faults in the Sensor Switch Box

• PLC inputs

• Other faults


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9.1 Fault messages of the Sensor Switch Box

If the Sensor Switch Box was configured though none is attached to the system, then the system emitsa fault message. In order to reconfigure the equipment to the correct adjustment “no Sensor Switch Box“,the unit must be switched off and on.The following message is displayed:

System Param.:12P12 LW:24-32mS/m no switchbox or defective

Picture: System does not recognize a Sensor Switch Box

After pressing the MENU key the following message is displayed:

System Param.:12P12 LW:24-32mS/mUDK20+switchbox? yes

Picture: Selection, if the Switch Box is to be operated

Adjustment for operating the Sensor Switch Box:

• yes: The equipment should continue operating with a Sensor Switch Box. The fault is cleared. If thefault condition is not eliminated, then the fault message appears again.

• no = CLR Param.: The equipment has to be reconfigured to operate without a Sensor Switch Box.All program parameters are deleted.

Attention: The deletion of the programs parameter cannot be undone.

The arrow keys allow the change between “yes“ and “no“. Confirm the selection with the ENTER key.


Rev. 1.0


9.2 Memory faults (faults no. 1 to 24)

1 Error while writing to the EEPROM. The acknowlegde signal does not arrive within the expected time.

The EEPROM is defective.

2 Error while writing to the EEPROM. No storage in memory possible.

The EEPROM is defective.

3 Parameter “Program Number” is out of range (> 255).

5 Parameter “Dimensions” is neither “mm” nor “inch”.

6 Parameter “Measuring mode” is - neither “external single measurement” - nor “external continuous measurement” - nor “demo mode”.

8 Parameter “Language” is not realistic.

9 Parameter “Sensor Switch Box” is not realistic.

12 Parameter “Measurement start” is not realistic.

15 Parameter “Teach-limit FE” is not realistic.

16 Parameter “sensor type” is not defined.

17 System parameter “Output 0-1-2” is out of range.

18 System parameter “External adjustment” is not realistic.

19 System parameter “FE measurement” is not realistic.

The memory errors 3 to 19 (except error 7) can be redressed as follows:

- Select the defective system parameter in the system configuration.

- Press the ENTER key, the corresponding

setting will the blink.

- Correct the value with the “Arrow” keys.

- Store the value with the ENTER key.

- Switch the unit off and on again, in order to check the new value.

7 Parameter “Zero-Adjust” is not realistic. Perform Zero-adjust.

20 Memory error XX. Unrealistic parameter in program XX. The program has been deleted.

Create a new program and store it. Switch unit off and on. If error re-appears, change EEPROM.

21 Memory error XX. Unrealistic parameter in program XX. Several programs have been deleted.

Since the numbers of the deleted programs cannot be indicated, check all programs. Switch unit off and on. If error re-appears, change EEPROM.

Table: Memory faults


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9.3 Zero adjust faults (fault no. 25 to 29)

25 The zero adjust value is not realistic. Perform new zero adjust. The sensor might have been covered with material.

Table: Zero adjust fault

9.4 Teach-in fault (faults no. 30 to 39)

30 The sheet cannot be taught, since no sheet is in front of the sensor or the sheet thickness is wrong.

Check sheet for correct thickness. Repeat Teach-In. If error re-appears, the sensor might be defective.

31 Automatic material detection is not possible. Select material manually.

32 For LM material (slightly magnetical) only material with a thickness of up to 2mm can be measured.

---

Table: Teach-in faults

9.5 RS232 Transmission faults (faults no. 40 to 49)

40 Cross-sum does not correspond to transmitted information.

Check program and data transmission path.

41 Incorrect dimension (MM instead of IN or IN instead of MM) or no numerical character at the expected position (e.g. -.50MM instead of 0.50MM).

Compare transmitted dimension and dimension in the parameter set at UDK 20. Numerical characters in the data format require a number. (e.g. 0.5000MM or 5.0000MM)

45 Transmitted value is out of the defined range (e.g. Program no. > 255).

Repeat data transmission with correct values.

47 The serial commands are following too fast. Include a small pause between the individual serial values.

48 A serial function was started while another serial function was still active.

Wait until the serial function is completed, then start the function.

49 Unknown command. Check command.

Table: RS232 Transmission faults


Rev. 1.0


9.6 Faults due to measuring operation (faults no. 50 to 54)

50 The AD converter or hardware is defective. Change AD converter / hardware.

51 The current between sensor and unit was interrupted during measurement.

Check cable and connectors. Check whether the sensor was removed during measurement (Counter-induction).

52 Measuring time is not realistic (too short). Exchange sensor.

53 Shortcut inside of sensor / sensor cable (also between lead and shiels).

Exchange sensor / cable.

54 Before measuring, the following items must have been performed: - nominal thickness was entered, - Zero adjust was performed, - Teach-In was performed.

- Enter nominal thickness, - Perform Zero adjust, - Perform Teach-In.

Table: Faults due to measuring operation

9.7 Keyboard faults (fault no. 55 to 59)

56 Parameters cannot be changed, since a parallel function is active (e.g. “Teach-In” or “Measurement start”).

Await completion of this function or stop it.

Table: Keyboard faults

9.8 Faults due to operating voltage (faults no. 60 to 64)

60 Operating voltage was below 20V DC. Check power supply.

62 Sensor voltage was too low. Check power supply.

Table: Faults due to operating voltagee

9.9 Sensor Switch Box faults (faults no. 65 to 69)

65 Error in the Sensor Switch Box. If a Sensor Switch Box is connected, check box and cables. Otherwise read the notes in chapter 9.1.

Table: Sensor Switch Box faults


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9.10 Faults parallel PLC inputs (faults no. 70 to 79)

70 Incorrect operation of PLC inputs. Check timing of PLC inputs.

71 Parallel function is not possible, since another parallel function is active (e.g. “Measurement Start” and additionally “Teach-In 1-sheet”).

See timing diagrams.

72 Selected program number exceeds 255. Select new program number.

73 Parallel function is blocked in the system configuration (ext. adjust: no).

If required, change configuration.

76 Parallel function is not possible, since the control unit was configured to „Internal control“.

For “Internal control“ only the measuring program can be selected. If required, change configuration to “External control“.

77 Parallel function is not possible, since the menue is open.

Close the menue.

Table: Faults parallel PLC inputs

9.11 Other faults (80 to XX)

> 80 An error has occurred, which cannot be unequivocally assigned to one of the above error classes.

Contact Roland Electronic Service Department.

Table: Other faults


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10. Maintenance

Generally, the Double Sheet Detector R1000 UDK20 requires no special or regular maintenance.If new types of sheet metal and dimensions are to be processed, then a new teach-in for new programs tobe stored is necessary, see also section 7.7.2 “Program parameter 8 - Teach-in“.In the following cases a new teach-in for all programs becomes necessary:

• If a sensor exchange was not done according to the instructions in the following section “Sensorexchange“

Note: Changes in metallic sensor brackets can change the measured value. Sensorbrackets made of metal with higher conductivity extract more energy from the sensor(and vice versa) due to the eddy current effect. Thus the stored programs lose theirvalidity.

10.1 Sensor exchange

In order to continue using the taught programs, the following must be observed:

• Before the sensor is removed, its installation position must be exactly documented. This appliesespecially to the installation position with regard to the measuring axis.

• The original installation position in all directions has to be restored. This applies especially for thegaps to the sheet.

Attention: If the original sensor positions cannot be restored, then the teach-in hasto be repeated for all programs.

After a sensor exchange the zero adjust must be made again. Procedure:

For a 1P-control unit with one sensor:

1. Ensure that no sheet is in front of the sensor

2. Press the MENU key, select “change“ and confirm with ENTER key

3. Enter the password

4. Change to “program parameter“ and confirm with ENTER key

5. Ensure that no sheet is in front of the sensor

6. Change to “zero adjust“, select “on“

7. Control unit shows “remove sheet“, Confirm with ENTER key

8. Control unit shows “zero adjust: active“, then “zero adjust: off“

9. Leave programming with MENU key


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For a 2PW-control unit with up to two sensors:

1. Check that no sheet is in front of the sensor resp. the sensors

2. Press the MENU key, switch to “change“ and confirm with ENTER key

3. Enter password

4. Switch to “program parameter“ and confirm with ENTER key

5. Check that no sheet is in front of the sensor resp. the sensors

6. Switch to “zero adjust“ and confirm with ENTER key

7. Select “zero adjust: separate“ or “zero adjust: common“

7.1 If “zero adjust: sepatate“, then confirm with ENTER

7.1.1 Display: “zero adjust S1: on / remove sheet“

If zero adjusts desired, then ENTER, or

if zero adjusts not desired, then activate “off“ and confirm with ENTER

7.1.2 Display: “zero adjust S2: off“

If zero adjusts not desired, then press ENTER, or

if zero adjusts is desired, then activate “on“ and press ENTER

7.2 If “zero adjust: common“, then confirm with ENTER, all connected sensors are zero adjusted.

8. The display “zero adjust: active“ appears, and then “zero adjust: off“

9. Leave programming with the MENU key.

10.2 Exchange of a Control unit

Exchange with help of the RPP-software (only with C-versions):The UDK20 provides for backup and re-writing the equipment parameters via the RS232 interface, with helpof the provided RPP-software.

Exchange without help of the RPP-software:After exchanging the equipment, the original system configuration must be restored. Therefor, the form„System Configuration“ in chapter „Technical Documents“ (which had been filled out during set-up) can beused. If this form is not available or filled out, the information on the system configuration must be retrievedfrom the equipment documentation.


Rev. 1.0


ROLAND

10.3 Exchange of the fuses

Picture: Position of the fuses in the R1000

10.4 Data back up via serial interface (only for C-version units)

The control unit provides for data exchange via the serial connection. The system and program parameterscan be stored in the PC via the serial RS232 interface (not for B-version units). In addition, stored or modifieddata can be written back again into the control unit.


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10.5 RPP-XP software (WinXP version)

Note: These brief instructions are valid only for the RPP XP-software.

The RPP XP- software is usable for the purpose of making a backup (safety copy) of the control unitconfiguration and systems parameters. In case of a defective control unit for example these backupparameter information can be transferred to another control unit

Hardware requirements- C-version of a ROLAND unit series R1000, such as E10, E20, I10, UDK10, UDK20 or

Fieldbus units- PC with Windows® 95/98/2000/NT/XP installed and a free serial interface or USB,

set at COM1 .. COM7- null modem cable for the serial interface, or USB-serial adapter

Installing the softwarePlace the supplied CD (No. 1) or floppy disc in the respective drive.In order to start the set-up program proceed as follows (this example assumes that theCD drive is „D“):

1. Windows button „Start“ > „Execute“2. Enter: „D:\setup.exe“ (the character depends on your system configuration)3. Confirm with „OK“4. Then follow the instructions on the screen.On installing, an entry „RPP-XP“ in the Start menü „Programs“ will be genereated.

Connection PC to R1000The ROLAND control unit and the PC must be connected via the nullmodem cable (part of thedelivered contents) or a USB-serial adapter cable.

The ROLAND control unit must be switched to the Back-up mode.

Measures at the device:

- press MENUE key- with arrow keys: change configuration- press ENTER key- with arrow keys: select Parameter Back-up- press ENTER key againThe unit signals „Parameter Back-up active“.

Starting the softwareAfter successful installation the software can be executed as follows:

Windows button „Start“ > „Programs“ > „RPP_XP“


Rev. 1.0


ROLAND

Screen layout


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Program operationRead data from the ROLAND control unit:

- After selection of the menu point „RPP_Data“ > „Read Roland device“ data is read from thecontrol unit. As described previously, the control unit must be in the parameter backup mode andconnected to the PC via a serial interface (COM or USB). The software automatically searchesfor the connected interface.

- Then the data are read. After successful data transmission the information is depicted as achart. Under the menue point „File“ > „Save“ the transmitted data can be stored under anarbitrary name. The file extension assigned by the program is „.RPP“.

- The table can be printed out with File > Print.

- If the data are not depicted as a chart, it could be necessary to register a FlexGrid ActiveX-Component.

Procedure:

- Copy the File msflxgrd.ocx from Program-directory to the windows system-directoryC:\windows\system32.

Then register the component withStart -> Run -> regsvr32 „C:\windows\system32\msflxgrd.ocx“After successful registration, the message „ DllRegisterServer ... succeeded“ appears.

Transfer data to the ROLAND control unit:- In order to reconstruct data use the function

„RPP_Data“ > „Write Roland device“.Again the ROLAND control unit must be connected to the serial interface of the PC and has tobe in the parameter back-up mode. You are prompted to select an available file which will thenbe transmitted to the control unit.

Help functions:

Under the menu point „Help“ > „Info“ you will find the ROLAND support address and the version number.In case of difficulties please call the indicated telephone number. Note the version number displayed.The menu point „Help“ > „Connection“ shows the required connecting cable.The menu point „Help > Help (english)“ shows this instruction.Help > FAQ (english) shows how to register the ActiveX Component.


Rev. 1.0


ROLAND

Pin configuration of COM interfaces(COM1 - D-Sub 9-pin; COM2 - D-Sub 25-pin)

Interface D-Sub 9-Pin

Pin Signal R1000

D-Sub 9-Pin Pin

R1000 - Fieldbus Round connector M8

Pin

R1000 internal

terminal block 1 carrier detector DCD 2 received data RxD 3 3 Pin 2 3 transmitted data TxD 2 2 Pin 3 4 --- 5 signal ground GND 5 1 Pin 1 6 data set ready DSR 7 request to send RTS 8 clear to send CTS 9 ---

Interface D-Sub 25-Pin

Pin Signal R1000

D-Sub 9-Pin Pin

R1000 – Fieldbus Round connector M8

Pin

R1000 internal

terminal block 1 protective ground 2 transmitted data TxD 2 2 Pin 3 3 received data RxD 3 3 Pin 2 4 request to send RTS 5 clear to send CTS 6 data set ready DSR 7 signal ground GND 5 1 Pin 1 8 carrier detector DCD

9–25 ---

10.6 Spare parts

Roland Electronic recommends to provide the following spare parts (minimum):

• One sensor

• One sensor cableWhether a spare control unit should be kept in provision has to be decided on individual basis.


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11. Technical information

11.1 Exchange of a R1000 UDK10 control unit against a R1000 UDK20 control unit

A R1000 UDK10 can be fully replaced by a R1000 UDK20. However, it is necessary that the control unithas the same suffixes, e.g.: UDK10-B-R by UDK20-B-R .The terminal blocks are pin compatible. Sensors and cables can be re-used. The previuosly used sensorPW42GS must be replaced by a sensor PW42AGS.

Controlling the unit via the PLC is identical. The response times of the UDK20 are substantially shorter thanthose of the UDK10 (see chapter 2.2 “Sensor data“).

It must be ensured that

- the power supply is capable to supply max. 60W for a UDK20 (max. 17W for UDK10), referred tochapter 2.5 “Technical data control unit UDK20“, and

- the cross-section of the supply cable is sufficiently dimensioned.

11.2 System configuration

Standard settings are shown in bold letters. Deviations from this standard are to be marked.

Language D ( ) E ( ) I ( ) F ( ) SP ( )

Sensor type: PW42AGS ( )

No. of sensors: 1 sensor ( ) 2 sensors ( ) 3 sensors ( ) 4 sensors ( )

Dimension: mm ( ) inch ( )

Meas. mode: Demo ( ) external single ( ) external continuous ( )

FE-Teach-Limit: 66% / 125% ( ) 33% / 142% ( )

FE Measuring (P): normal ( ) fast ( )

Password: yes ( ) no ( )

Level 0,1,2-sheet: 0V DC ( ) +24V DC ( )

External adjust: yes ( ) no ( )

Unit version: ____________


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12. Order data

12.1 Versions of UDK20

Order data Description

UDK20-B-R-S Control unit in wall mount enclosure, memory for 255 parameter sets, programming via keys, 9 potential-free data inputs 24 VDC with joint common, relay outputs

UDK20-B-R-S-FP As UDK20-B-R-S, but control unit in front panel enclosure

UDK20-B-O-S As UDK20-B-R-S, but with opto coupler outputs

UDK20-B-O-S-FP As UDK20-B-O-S, but control unit in front panel enclosure

UDK20-C-O-S As UDK20-B-O-S, plus 1 potential-free RS232 interface for data backup

UDK20-C-O-S-FP

Uni

t with

1 s

enso

r or

SS

B

As UDK20-C-O-S, but control unit in front panel enclosure

UDK20-2PW-B-R-S Control unit in wall mount enclosure, memory for 255 parameter sets, programming and operation via keys, 9 potential-free data inputs 24 VDC with joint common, relay outputs

UDK20-2PW-B-R-S-FP As UDK20-2PW-B-R-S, but control unit in front panel enclosure

UDK20-2PW-B-O-S As UDK20-2PW-B-R-S, but with opto coupled outputs

UDK20-2PW-B-O-S-FP As UDK20-2PW-B-O-S, but control unit in front panel enclosure

UDK20-2PW-C-O-S As UDK20-2PW-B-O-S, plus 1 potential-free RS232 interface for data backup

UDK20-2PW-C-O-S-FP

Uni

ts w

ith m

ax. 2

sen

sors

As UDK20-2PW-C-O-S, control unit in front panel enclosure

Table: Order data UDK20 versions

12.2 System accessories


SSBUDK10 Sensor Switch Box, for connecting of up to 4 sensors (not for UDK20-2PW versions)

Table: Order data system accessories


Rev. 1.0


ROLAND

12.3 Sensors and accessories


PW42AGS Sensor 42 mm Ø, without cable, but with sensor plug for sensor cable connection, sensor with threaded body M42 x 1.5 mm, 2 flat nuts

SH42GS Spring loaded sensor bracket for direct installation of sensors with thread body M42 x 1.5 mm

SP42GS Suction cup

SHS42GS Spring loaded sensor bracket or direct installation of sensors with threaded body M42 x 1.5 mm, with vacuum cup, without clamping bracket

SHK Clamping bracket

SHS42G-FB Sensor bracket, spring suspended, with bellow suction cup, red, 45 Shore

2395045 Suction plate, for bellow suction cup, red, 45 Shore

2395046 Suction plate, for bellow suction cup, black, 60 Shore

2395110 Spare rubber lips for sensor bracket SHS42 or suction cup SP42

2395109 Spare rubber pad for suction cup SP42GS and for sensor bracket SHS42GS

Table: Order data sensors and accessories

12.4 Cables

Standard cable length is 5m. Customized lengts up to 50m can be ordered.The following cables can be ordered.

Order data Specification Description

SCPWS-GG Superflex-(C) Y PURKOMBI, 2 x 1 mm2 + 4 x 2 x 0,25 mm2

Cable for connecting sensor PW42AGS to UDK20 or to SSBUDK10, both cable ends with quick disconnect plug, straight cable plug for connecting the control unit, straight socket for connecting the sensor

SCPWS-GW Superflex-(C) Y PURKOMBI, 2 x 1 mm2 + 4 x 2 x 0,25 mm2

Cable for connecting sensor PW42AGS to UDK20 or to SSBUDK10, both cable ends with quick disconnect plug, straight cable plug for connecting the control unit, right angle socket for connecting the sensor

SVCPWS-SSBUDK10 Cable, 2 meters Cable for connecting UDK20 to SSBUDK10, both cable ends with quick disconnect plug, straight cable plugs on both sides

Table: Order data cables


B0048991


12.5 Cable plugs and cable sockets


2277004 Cable plug (to control unit), 6+3 pin, Coninvers series RC

2276005 Cable socket with securing ring, 6+3 pin, Coninvers series RC

2276007 Right angle cable socket with securing ring, 6+3 pin, Coninvers series RC

22K4210 Cable without plug, Superflex-(C) Y PURKOMBI, 2x1 mm2 + 4 x 2 x 0,25 mm2

Table: Order data cable plugs and cable sockets

12.6 Other accessories


RPP Software for data backup

SM8KRS232D9S Cable for RS232 connection to PC, 3m length

Table: Order data other accessories