microsonic dbk+5/Empf/3CDD/M18/ K7K2 Ultrasonic Double Sheet Detection With 2 Switched Outputs Instruction Manual

Operating Instructions
Ultrasonic double sheet detection
with 2 switched outputs
dbk+5/Empf/3CDD/M18/ K7K2
dbk+5/Sender/M18/K1

Functional principle

The function of the double sheet detection is to detect two or more sheets or other laminary materials lying one on top of the other. The sensor system consists of a transmitter and a receiver complete with integrated evaluation electronics.
A high-frequency ultrasonic transmitter beams from the underside against the sheet material. The emitted ultrasonic pulse excites the sheet material into vibrations. The effect of these vibrations is for a very small sonic wave on the other side of the sheet to spread. This wave is received by the ultrasonic receiver located there. In the case of sheet one on top of the other (double sheet), the receiver detects the difference in signal and sets its outputs accordingly.

Product description

• Assured detection of single, double and multiple sheet.
• Scanning of sheet material weights from 100 g/m 2 to 2,000 g/m 2 , corrugated cards, sheet metals, printed circuit boards, films and plastic sheets up to several mm thickness possible.
• Double sheet and missing sheet output as pnp switching outputs.
• Vertical mounting to the sheet running through permitted.
• Three control inputs allow for an external setting of sensitivity for the material to be scanned.
• Changes to sensitivity classes under ongoing operations can be undertaken.
• Additional teach-in mode e.g. for scanning wafers glued with a water film.
• Optional trigger operation mode e.g. for applications in the shingled stream.
• Parameterization via LinkControl
• 0.5 ms response time until a double or missing sheet in the trigger mode is detected.
• Transmitter-receiver spacing can be selected from 30 to 70 mm Safety tips
• Read the operating instructions before start-up.
• Only qualified personnel are to undertake connection, mounting and settings.
• Not a safety component in keeping with the EC Machinery Directive.

Mounting

• Mount transmitter and receiver in keeping with Fig. 3 at the recom- mended spacing of 50 mm ± 3 mm. dbk+5 can be fitted at any position.
• Connect the transmitter to the receiver using the M8 connector.
• Connect the receiver 7-strand control line in keeping with Fig. 1.

| colour
---|---
+UB| brown
–UB| blue
Single/missing sheet output| black
Double sheet output| white
Control input C1| violet
Control input C2| pink
Control input C3/Com| grey

Fig. 1: Colour coding of the control line

Pointer

• If required, spacing between transmitter and receiver can be adjusted to the local circumstances in the 30 to 70 mm range; see under »Teachin spacing between transmitter and receiver«.
• The coaxiality of transmitter and receiver must be ≤0.5 mm.
• Transmitter and receiver are not to be inclined to each other in excess of 2°.
• Vertical mounting to the sheet is recommended for papers (Fig. 3a).
• In case of vertical mounting to the sheet, the spacing between transmitter and/or receiver and the sheet running through is not to be under 7 mm.
• In case of certain sheet metals or thicker plastic films, the dbk has to be mounted at an inclination to sheet normal depending on the material (Fig. 3b). If necessary the optimum mounting position has to be determined in a test.
• Thick papers and paperboard responsible for faulty switching in case of vertical mounting can often be scanned at a 27° to 45° mounting angle to sheet normal. Corrugated cards have to be measured obliquely to the waves (Fig. 3c).
• Other materials may make a special fitting position necessary. Do con- tact microsonic when you work with these special materials.
• The max. torque of the nuts is 15 Nm for the M18 sleeves.
• The drill hole must be ≥ 12 mm given that the transmitter is recess- mounted or a sheet feed is envisaged between transmitter and receiver. The recommendation is for a 18 mm diameter (see Fig. 3).
• The line between transmitter and receiver is not to be bridged with an external potential.

Start-up

• Select the »Standard« sensitivity class by placing all the 3 control inputs onto logic 0 (see Fig. 4 and Fig. 5) or leave them unconnected.
• Switch on the dbk+5 voltage supply.

Pointer
The »Standard« sensitivity class corresponds to the setting of predecessor model dbk-5. Check the function with a test sheet:

• Hold a single test sheet within the working range between transmitter and receiver. The LED must light up green for »Single sheet detected«. Should the LED light up red, then check on the dbk+5 fitting dimension and the selected test sheet.
• Hold a double test sheet within the working range between transmitter and receiver. The LED must light up red for »Double sheet detected«.
• Remove all the sheets between transmitter and receiver. The LED must flash red for »Missing sheet detected«.

Pointer
You can use a material of a high sheet weight as the test sheet or the test sheet itself obtainable as an accessory with the »dbk test sheet« article name. This test sheet works as critical material at the ambient temperature in the »Standard« sensitivity class and can be used to examine the correct adjustment and function.

Factory setting

The dbk+5 are delivered with the following factory settings:

• Free-run mode with 3 sensitivity classes and teach-in
• Missing sheet output on NCC
• Double sheet output on NCC
• 50 mm spacing

Condition| LED 1| LED 2|
---|---|---|---
single sheet| green| green| static on
single sheet overmodulation| green| green +
red =
orange| static on
double sheet| red| red| static on
missing sheet| red| red| flashing
Teach-in activated| green| green| flashing alternately
Teach-in dismissed| red| red| flashing alternately
Teach-in spacing transmitter-receiver| red| green| flashing alternately

Fig. 2: LED displays Fig. 3: Mounting and installation positions
Operation in the free-run mode
The dbk+5 operates in the free-run mode ex-works. In the free-run mode, the dbk+5 performs measurements cyclically.
Pointer
If measurements should be taken in the shingled stream, then an external trigger signal can individually trigger each measurement. To this end, the trigger mode can be parameterized with the help of the LCA-2 LinkControl adapter available as an accessory and the LinkControl software.

Fig. 4: Voltage level of the logic states at the control inputs

Sensitivity classes

The fact that the dbk+5 control inputs are unconnected or on logic 0 points to pre-selection of the »Standard« sensitivity class where the range of sheet material weights from a typical 100 g/m 2 up to 2,000 g/m 2 can be scanned.

• The 3 control inputs allow the sensitivity classes to be pre-selected in keeping with the Fig. 5 table.
• The »Thin« setting has to be selected for thin materials.
• The working range can be enlarged to thicker materials by choosing the setting »Thick«.
• Changes between sensitivity classes can be undertaken under on-going operations.
• Pre-selecting an over-low sensitivity class can result – even with a single sheet – in a double sheet signal appearing. In such an instance, the next-higher sensitivity class is to be pre-selected.
• Pre-selecting an over-high sensitivity class results – given a single sheet – in the double-sheet detection indicating overmodulation at the LEDs: one LED lights up green and the other green-red (orange blend). In such an instance, the next-lower sensitivity class is to be pre-selected.

Pointer
Parameterization of the D1 switched output onto the »Overmodulation« output function achieved with LinkControl software results in the overmodulation signal being additionally outputted on D1.
Teach-in
The teach-in mode is also available for materials glued to each other across their full extent (e.g. two wafers bonded with a water film, a spline on a paper web) and special materials which cannot be scanned with one of the 3 sensitivity classes.

• Select the teach-in mode (C1 and C2 on logic 1) in keeping with the table in Fig. 5.

This is the way to teach-in a material:

• Place a single sheet of the material in the working range of the double sheet detection.
• Place the C3 control input on logic 1 for a minimum of 3 seconds. Materials with inhomogeneities must be moved during the teach-in phase so that dbk+5 can detect them.

Success with a teach-in operation is shown by a green LED. In instances of where no material teach-in was possible, dbk+5 flashes in red. Then repeat the operation.

• On finishing the teach-in operation, either place the C3 control input on logic 0 or leave it unconnected. The material can now be scanned.

Pointer
C3 must not be on logic 1 when the supply voltage is connected.

| C1| C2| C3
---|---|---|---
Standard| 0| 0| 0
Thick| 0| 1| 0
Thin| 1| 0| 0
Teach-in-Mode| 1| 1| 0
Teach-in active| 1| 1| 1

Fig. 5: Free-run mode: selection of the sensitivity class and Teach-in
Parameterization with LinkControl
The dbk+5 can be extensively parameterized under LinkControl. Here you need the optionally available LinkControl adapter LCA-2 and the LinkControl software for Windows © .
Operation onto LinkControl

• Install the LinkControl software onto your PC. Connect the LinkControl adapter to your PC with the USB cable.
• Connect dbk+5 to the LCA-2 in keeping with the Fig. 6 table. For this, use the adapter cable in the LCA-2 case.
• Connect the voltage supply cable to the LCA-2 on the other side of the T connector.
• Start the LinkControl software and follow the instructions on the screen.

| Colour dbk+5| Colour adapter cable| Pin
---|---|---|---
+UB| brown| brown| 1
–UB| blue| blue| 3
C3/Com| grey| grey| 5

Fig. 6: Connecting dbk+5 to the LCA-2

The following settings can be undertaken:

• Numeric input of the spacing between transmitter and receiver
• Function for the D1 switched output Missing sheet = NCC (single sheet = NOC) or Missing sheet = NOC (single sheet = NCC) or Overmodulation = NCC or Overmodulation = NOC
• Function for the D2 switched output Double sheet = NCC or Double sheet = NOC
• Operating mode Free-run mode with 3 pre-defined sensitivity classes and additional teach-in mode or Free-run mode with 4 indepen-dent teach-in classes or Trigger mode with 2 pre-defined sensitivity classes and additional teach-in mode or Edge- or levelcontrolled trigger mode

Also available is a diagrammatic representation of the readings.
Operation in the trigger mode
If LinkControl was used to parameterize the trigger mode, then the external trigger signal is to be placed on the C2 control input. Available in the trigger mode are sensitivity classes »Standard«, »Thin« and the teach-in mode in keeping with the Fig. 7 table. In the edge-controlled trigger setting (see Fig. 8), the double sheet detection takes a measurement with every edge from 0 to 1. The finding is then stored until the next trigger edge.

| C1| C2| C3
---|---|---|---
Standard| 0| Trigger| 0
Thin| 0| Trigger| 1
Teach-in-Mode| 1| Trigger| 0
Teach-in active| 1| Trigger| 1

Fig. 7: Trigger mode: selection of the sensitivity class and teach-in mode
In the level-controlled trigger mode, dbk+5 keeps on taking measurements for as long as the trigger signal is on hand. With dbk+5 deactivated (C2 control input to logic 0), the reading of the last measurement at the switched outputs is frozen (see Fig. 9).
Fig. 8: Trigger mode edge-controlled
Free-run mode with 4 independent teach-in classes
Parameterization with the aid of LinkControl of the free-run mode with 4 independent teach-in classes makes teach-in possible for up to 4 different materials. As a result, the »Standard«, »Thick«, »Thin« and »Teach-in mode« sensitivity classes can be individually adjusted (see online help in LinkControl).
Teach-in spacing between transmitter and receiver
Teach-in of the selected spacing between transmitter and receiver must be undertaken should you not have mounted transmitter and receiver at the recommended 50 mm spacing.

• Clear the measuring section of sheet materials between transmitter and receiver.
• Place all the 3 control inputs on logic 1.
• Switch on the supply voltage: The LEDs flash alternately red and green.
• Wait at least 2 seconds. Place the C3 control input on logic 0.

Pointer
Any failure to teach-in the set spacing results in dbk+5 flashing in red for 3 seconds.
dbk+5 is operating normally.

• Finally, select the requested type of operation through the control in- puts.

Maintenance

No maintenance is need on the double sheet detection. We would re-commend cleaning the sensor surfaces at the transmitter and receiver should they become very dirty. The best thing is to apply some isopropanol onto a cotton cloth and then wipe the surface clean. Make sure that the reaction time of the cleaner is kept down. That means quickly wiping dry the transducer surfaces.
Fig. 9: Trigger mode level-controlled

Technical data

dbk+5/Empf/3CDD/M18/ K7K2

laminated sheets and films up to 5 mm thickness, self-adhesive films, sheet metals up to 2 mm thickness, corrugated cardboard, wafer, printed circuit boards
operating voltage UB| 20 to 30 V DC
voltage ripple| ±10 %
no-load current consumption| ≤50 mA
type of connection| 7 m PUR cable, 7 x 0,25 mm
transmitter-receiver connection| At receiver: PUR; 2.3 m; at transmitter: 1 m, PUR; both with 3-pin M8 plug
controls| 3 control inputs: C1 to C3
programmable| selection of sensitivity classes, Teach-in, LinkControl
Response time Trigger-Mode 1)| <500 µs
Response time Free-Run-Mode 1)| 5.5 ms
release delay Trigger-Mode| until next edge
Release delay Free-Run-Mode 1)| 5.5 ms
indicator| green: working/single sheet
red: double sheet
red flashing: missing sheet
housing| brass sleeve, nickel-plated; plastic parts: PBT, PA;
cable: PUR; ultrasonic transducer:
Polyurethane, epoxy resin with glass content
max. tightening torque of nuts| 15 Nm
class of protection to EN 60529| IP 65
operating temperature| +5 to +60 °C
storage temperature| –40 to +85 °C
weight| 150 g
norm conformity| EN 60947-5-2
order no.| dbk+5/Empf/3CDD/M18/ K7K2
dbk+/Sender/M18/K1
double sheet output| pnp, +UB–2 V, Imax. = 200 mA, short circuit proof, switchable NCO/NCI
missing sheet output| pnp, +UB–2 V, Imax. = 200 mA, short circuit proof, switchable NCO/NCC
UE at control inputs C1-C3| > –UB+18 V: logical 1
< –UB+13 V or control input open: logical 0
time delay before availibility| <300 ms
pin assignment

1. can be programmed with LinkControl|

microsonic GmbH
Phoenixseestraße 7
44263 Dortmund
Germany
T +49 231 975151-0
F +49 231 975151-51
E [email protected] 
W microsonic.de
The content of this document is subject to technical changes.
Specifications in this document are presented in a descriptive way only.
They do not warrant any product features.

References

• microsonic | ultrasonic sensors | Made in Germany

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