Chapter 4: Wiring Inputs: ‘The figure below shows a portion of a typical input circuit schematic. The inputs are rated for 24 VOC, ‘and each will draw typically 6 mA. The inputs are opto-isolated, but they share a common line. This line may be connected to either the high side or the return side of the 24-volt power supply. In other words, the inputs can be driven from either current sourcing or current sinking outputs but cannot be mixed. ‘There are earlier versions of the DBA family, which required current sinking outputs in the PLC to drive the DBA inputs. Ey INPUT. am ty veut common outputs: The figure below shows a portion of a typical output circuit schematic (the fault output is described separately). ‘They are rated for 24 VDC and can supply 100 mA, ‘The outputs are optovisolated, but they share a common line (NOT the same common line which the Inputs share). This line may be connected to either the high side or the return side of the 24-volt power supply. In other words, the outputs can source or sink ‘current but cannot be mixed. There are earlier versions of the DBA family whose outputs could only sink current, Ty cet] | 4 ce ourpuT ‘ourput OUTPUT COMMON Output Circuit ‘The input and output signals of the DBA are optically Isolated, solid state signals which require 24 VDC for operation. This 24 VDC supply can be a separate external supply, or the internal 24 VOC (unregulated) supply of the DBA can be used. The internal supply is limited to 300 mA, and the low side of this supply is, internally connected to earth ground. To retain full isolation of the input/output signals from the intemal circuitry of the DBA and any extemal control device, an extemal 24 VDC power supply should be used. If full solation is not required, the internal unregulated 24 VDC supply of the DBA can be used to drive the input/output signals. Fault Relay: In addition to the 1/0 signals, a fault indicating relay contact is provided to alert an external control of an internal fauit condition detected by the DBA. This contact is closed during normal operation and opens when a fault occurs. The contacts are rated for 6A @125VAC or 2 @30VDC,‘UV Dd 3H OL AO GNY G YO 3 STNINYSL OL DAA $24 L93NNOD- 3YNOS HL SI VEG st “GuVD 97d SHI O GA 92+ NY G YO a STVNINYAL O4 AO.LO3NNOD - MINIS BHI SIVEG I 'JOUNOS LN3YAND YO WNIS LNIWMND V SV GAYIM 3E NYO Ol JOVANGINI D7d VEO SHI - ALON Non-lsolated 24 VDC Interface (internal 24 VDC supply) Single Channel DBA - 120 or 240 VAC Input i annous 9} — a 0 ew yusone avuinan a }-— ) 7aev7 vea No NoULWNoISaa Sanve nant nstaNoo = ON iv ann 2H on05 OYA OF 30 008 A 1 Nowlanoo JoviNoo Winv4 NO i Avy LInW4 y10373S # LT vec s 'SN3d0 LOVLNOD | —— var ¢ Loa1as ziosas |# ° vasanve visas |? ree ice 1 re oT saer Tavis pe +l aso aan | Zines va Anant od 2 Nownoa inaino Nomad inant Io lnaino o14 ubwousno weWOLSRO cock chock Hil = tii cts ae co 310N338 310N a3 4.Single Channel DBA - 120 or 240 VAC Input lsolated 24 VDC Interface (external 24 VDC su ‘dYVO 01d 3HL OL AO NY G:YO 3 STWNINAL OL DOA #Z+ L93NNOD ~ 39UNOS 3HL SI VEC sl ‘GUY 01d 3HL OL DUA 2+ GNV G YO 3 STNINAL OL AO 193NNOD - MINIS 3HL SI VEC st "BOUNDS LNSWYND HO HINIS INGYUND ¥ SV OFUIM 3G NVD OM SOV4RGINI O1d VEG 3HL- ALON |_F s2ev1vaa no nouwnoissa Lv10% = oNnoHD D ANANI WalNOD ~ 3L¢ cauvi0s! = s130¥aUSINI iw NO eeu yuo cpeaunan 2409/05 OVA 0¥z 30 OZ a1 36 10N Sane ANALNO SGA vz lw * ann ¥ nowanos { —]F—L 19¥aNoo viomas | “rinvs NO 7 we 5 ‘SN3d0 LOVLNOD W €.10373S ziomss |* "| Savisanve 7 Tiosas |? 4 Teaez | pat 1 }° |asaHs + To LaVLS 4) Ta3ns0 mi avnnxny |* NaSaee Lave nant an 2} Nonmnos inane NOWWGS IneNT Lo | linaino O14 esnoisn| ‘waMOLSNO rook ee to aun rit 0 piu nee cI Te ttt 4+ [+ ann BION 33S alow 33sSingle Channel DBA - 24 VDC Input ly) Isolated 24 VDC Interface (external 24 VDC su ‘OuYD O14 3HL OL AO GNY G HO a STVNINYSL O1 90A #Z+ L9ANNOD- 3OUNOS AHL SI VEC SI ‘dO O14 HL OL OGA 92+ GNY G NO 3 STYNINSL O4 AO 193NNOD - ¥NIS 3HL SI YEG 3 “3oUNOS LNaUUND HO NNIS LNaMUND V SY GMM 3a NYO ON FOVIUBINI Td VEO 3HL-BLON : |= wen ysononouwnesa ‘81 30V-4ALNI N ND xu ywooe no 8 TNs OGRE fn : e zioaas |* "FawHsanve visas |¢ HT SiaaHs 2 | : Phaser [Oa I tf ‘Ease Tarn)" AndNi O14 [3 | NOWNOD InaINO Nonmnao inant 2] jinaino o14 roca moi ‘anez, no reid no riot | trot ro tt + BION 338 310N 338Multi-Channel DBA — 120 or 240 VAC Input Non-Isolated 24 VDC Interface (internal 24 VDC supply) SEENOTE SeENoTe mio ov mo customer [5 jimeur coumon curvt conmon | cxsrower| sigouwer 5 on memnur oawa Er, | sau al “ 4 sneer b neers nave cone amet) =| Auman + [star "| veers ~ 3 __Hanosie oO cane rar ree | Avauas c wae] fo toe » ~ neers vamos | ‘eano a woman Suet | vane ‘ a} po —__tsneers| L~_nosuane| ‘contact | TC} onan savor vac sent: (la une sore-conrm net savor vesiotation onsentasee |—lo neurea. Joona mex 2 sro NOTE -THE DBA PLC INTERFACE HO CAN BE WIRED AS A CURRENT SINK OR CURRENT SOURCE. 'F DBAS THE SK - CONNECT eV TO TERMINALS E OR D ANO +24 VOC TO THE PLC CARO, \F DBAS THE SOURCE -CONNECT #24 VDC TO TERMINALS E OR 0 AND OV TO THE PLE CARD.Multi-Channel DBA — 120 or 240 VAC Input Isolated 24 VDC Interface (external 24 VDC supply) sr sa et vars of . a fe ] oe AUXILIAE MEET start ~o 1s} 1h | chane [Ava ASIEET * 2 SHEETS | aa amas} = ‘customer | eae [|weur cons ‘oupur couson. .| owe tte | starr iW ~ asneers| Gy HANDSHAKE: sevecr 2 ooo rL~) contact ovens scuecr raucrnetar = | Surauur | ‘onracr T_| ,|_— J eonomen oo |__|, |seuecr sc | une or id Norse 120 or 20 VAG aso We in {eam mae —|_— f irenrace's NOTE -CONFIRAINPUT —F~ 1c oRouNo esionarion owosa case, £ NOTE. THE OBA PLC INTERFACE 10 CAN BE WIRED ASA CURRENT SINK OR CURRENT SOURCE. VFA 8 THE SINK-.CONNECT OV TO TERMINALS E OR B AND +24 VOC TO THE PLE-CARO. IF DBA|S THE SOURCE -CONNEGT #24 VDC TO TERMINALS € 08 0 AND OV TO THE PLC CARD.Multi-Channel DBA — 24 VDC Input Isolated 24 VDC Interface (external 24 VDC supply) evens on scene 7 i - [custowen| ‘CUSTOMER PLeINPUT pucoureur ‘ouPuT common [= |weur common = ~~ parr presen ‘sneer a sweers. ~o_HANDSHAKE — ~~ wast Rese ~2 tier ssueer wo 28018 | 2 _tanosuiane | ‘PART PRES ~ 20H | ssneer| 2sHeErs po __Hanoste | — PART PRESERY a OSHeeT 1 seer scvect2, seecr seuecté et] T} ova FAS ONTAGT Soxorron ‘eontacr LC ,|— supe * Noruseo 2avoc weut ion SedmAmat. gy [_ ore -cONFIRM INPUT Je oRouNo t INTERFACE S| aw (oc! gee ‘ovate. MOTE - THE 084 PLC INTERFACE UO CAN BE WIRED AS A CURRENT SINK OR CURRENT SOURCE. 1 OBA ISTHE INK - CONNECT OV TO TERMINALS E ORD AND #24 VDC TO THE PLC CARO, \F OBA 18 THE SOURCE - CONNECT +24 VOC TO TERMINALS E OR 0 AND OV TO THE PLE CARD.Single-Channel Control Cable: elu wat sree SWAB TRE oa sipMulti Channel Control Cable:Chapter 5: Interface Signals and Programming Considerations AA single channel DBA has 6 inputs and 4 outputs. Multiple channel DBA's add 2 inputs and 4 outputs for each ‘additional channel beyond channel A. All inputs and outputs are optically Isolated and can be wired for current sinking and current sourcing operation. Wiring diagrams on pages 4-1 to 4-7 provide typical wiring information for both types of interface. Select the wiring diagram that is compatible with the type of I/O cards used in your PLC. Remote Preset and Function Selections ‘The DBA has 4 inputs labeled Select 1, Select 2, Select 3 and Select 4. These inpuls are used to select one of 12 preset single sheet thickness values that the user has programmed into the DBA. These inputs can also be used to test the operation of all outputs, initiate a Learn command and clear fault conditions by PLC input. ‘The inputs are turned on in a standard binary format to select the active preset number or initiate special functions. The inputs must be held stable for 100 milliseconds to insure proper operation, Terminal Designations Select 4 ‘Select 3 Select 2 Select 1 FUNCTION Binarys | Binary4 | Binary2_| Binary 4 ° ° o ° LOCAL PRESET SELECTION ° ° ° fl PRESET THICKNESS 1 ° ° i o PRESET THICKNESS 2 ° ° 1 1 PRESET THICKNESS 3 ° 1 ° 0 PRESET THICKNESS 4 ° 1 ° 1 PRESET THICKNESS 5 ° 1 i ° PRESET THICKNESS 6 © 7 H 1 PRESET THICKNESS 7 1 ° ° ° PRESET THICKNESS @ + ° ° 1 PRESET THICKNESS 9 1 ° 4 2 PRESET THICKNESS 10 7 ° z fl PRESET THICKNESS 11 1 1 ° ° PRESET THICKNESS 12 1 1 0 1 TEST OUTPUTS: 1 1 1 ° INITIATE LEARN 1 1 1 4 CLEAR FAULT. ‘The above chart shows the binary inputs used to select presets or functions. At" indicates that the input is ON. A “0” indicates that the input is OFF. Preset Thickness Selection - When all inputs are tured off, the display will show "LOCAL in its upper right hand. corner. All keypad-entered functions can be accessed when in the LOCAL mode including preset selection any signals to these inputs will result in “Remote” on the display. Many keypad functions are inhibited when remote is displayed. A integrator Note ~The plant evel usr of the DBA must be provided win a PLC sreen command {rat trns of al inputs o St, G2, 59 and Sto slow aooss to weyoadfuncon,lesce rear yor Spproach fo proving ths inton onthe system salup recom Append A binary input of 1 through 12 will access the 12 memory locations provided for the storage of preset single blank thickness values. The 12 thickness values are programmed in the field to reflect the range of material thickness specific to the press line or application. See page 2-6 for programming details.A integrator Note — Please document the preset thickness valos tat your loi expects nach Imemor locaton onthe systems setup recerd in Appendi A. The pan va users ofthe OBA system wl need to deplete your bickness choices whenever DBA conrolrs ar replaced Test Outputs A binary 13 input forces all DBA outputs “ON to test their operation. This function can be helpful for troubleshooting suspected interface problems. The word “TEST” will appear on the display whenever this function is active, Learn — A binary 14 input initiates a learn function. See page 2-18 for details and cautions on the use of the learn function. The work “LEARN will appear on the display whenever this function is active. Clear Faults ~ Operational faults within the DBA system will result in a fault indication on the display and the system fault relay will deenergize. See page 7-1 for detals on fault conditions and their display messages. The fault must be corrected and a clear fault command sent from the PLC or the keypad "EXIT" key is. pressed to clear the display, energize the fault relay and resumes normal operation. The word "CLEAR" will ‘appear on the display whenever this function is active. ‘This input has nothing to do with clearing a 2-sheet condition detected during normal operation of the DBA system. The “2 sheet” output for a channel is cleared by removing the 2 sheets from the sensor face followed by taking a new sensor measurement, Auxiliary Input ‘The auxillary input can be configured for Mode Selection, Fault Disable or Material Selection Early versions of the DBA and their wiring diagrams used this input for selection between “Mode 0° and "Mode 1" operation. "Mode 0° and "Mode 1° operation specifies very distinct differences in the sequence in which measurements are taken and the meaning of the Part Present / 0 Sheet output. It is highly unlikely that a system would ever cycle between “Mode 0" and “Mode 1” operation so connection of this input to 2 PLC is not required. If the auxillary input is used for Mode 0 / Mode 1 selection, we recommend leaving the input disconnected for Mode 0 cr permanently turned on with a jumper wire for Mode 1. ‘Current versions of the DBA software allow permanent selection of Mode 0 and Mode 1 operation from the keypad, ‘See VIEW CHANNEL functions on page 2-9 and 2-11 for programming details. The auxillary input can now be Configured for fault disable or material selection functions as outlined later in this section. Mode 0 sequence - A single thickness measurement is initiated immediately upon seeing an off to on transition of the “start” input. The appropriate 1 sheet or 2 sheet output tums on based upon the measured thickness and ‘selected preset thickness value. This output will remained latched unil the next measurement is initiated by another OFF to ON transition of the start input. The output labeled “Part Preset / 0 Sheet” operates as a part present output in Mode 0. This output turns ON whenever material is sensed in front of the sensor face and turns OFF when material is not present. It operates totally independent of the start signal and will continuously turn ON or OFF based on the presence or absence of ‘material in front of the sensor. Multiple start inputs will result in multiple thickness measurements. The maximum rate of the start inputs should not ‘exceed one start every 150 milliseconds for 42mm and 54mm Ferrous sensors. The maximum start input rate for the 75mm Ferrous sensor should not exceed one every 250 miliseconds. Higher rates can overheat the sensor and decrease measurement accuracy. ‘The Non-Ferrous sensor can operate at start input rates of one every 32 milliseconds. Heat build-up is not 2 concern, Non-Ferrous »nsors will only operate in “Mode 0” if programmed for single measurement mode operation. Ferrous sensors can be configured to operate in “Mode 0” as outlined above or in the “Mode 1” sequence ‘outlined below.Modet Sequence - The start input from the PLC prepares the sensor for a measurement. A thickness measurement does not occur until ferrous material is detected by the 1mm range proximity switch in the face of the sensor. A single thickness measurement is then initiated and the appropriate 1 or 2 sheet output turns on based Upon the measured thickness o preset thickness comparison. The start signal must be received before material is. detected in front of the sensor. The output labeled "Part Present / 0 Sheet’ operates as a 0 sheet output in Mode 1. It turns on whenever the measured thickness falls below the preset tolerance window. See pages 2-6 and 5-5 for details. ‘The term "0 Sheet Output" may be misleading, The output turns on based on a “thin sheet’ condition. A true 0 sheet condition can never be measured because a measurement is not taken until ferrous material is detected by the sensor proximity switch. The outputs remain latched until the start signal is removed. Fault Disable {A disconnected sensor cable will cause the display to lock on a "Sensor disconnect’ fault message and the fault relay will deenergize. The system remains in this condition until the sensor is reconnected and the “Exit” key is. pressed. This is a desirable fault sequence during normal production use where all sensors are looking for a ‘multiple blank condition. However, there are situations where this fault condition and clearing sequence is not ‘wanted. Automated tool change sequences can result in momentary sensor disconnect conditions and all sensors, may not be used on certain production jobs. The auxiliary input can be configured to prevent sensor disconnect faults by using the setup programming described under “VIEW CHANNEL" on pages 2-9 and 2-12. The input is then turned on prior o disconnecting the sensor and held on until the sensor is reconnected. This prevents the normal fault condition from occurring and eliminates the need for the fault clearing sequence outlined above. A typical use for this feature is during automated tool change sequences. The input is turned on prior to disconnecting the tool on which a DBA sensor is mounted. The new tool with DBA sensor is then connected during the automated tool change sequence. The input is then turned off to retum that DBA sensor channel to normal operation, Mat ial selection (Non-Ferrous driver circuits only) Non-Ferrous input channels use different internal conversion curves to calculate the thickness of non-ferrous (aluminum, brass, etc.) and stainless steel. These same materials may need custom conversion curves derived by calibration using actual samples of the material being processed, Systems that process a wide range of different non-ferrous materials may need to store multiple conversion curves in the DBA that are recalled by the PLC as various jobs become active. The auxiliary input can be configured to allow the selection of two different conversion curves by the PLC. See VIEW CHANNEL setup procedures on page 2-12 for details. The setup sequence allows you to establish two different nonferrous and two stainiess steel conversion curves. Two of these four possible curves are then tied to the auxiliary input. One curve will be used when the input is turned on and the other curve is used when the input is off. This allows a system to monitor aluminum on one job and then change to stainless steel for the next job with ‘material selection being controlled by the PLC. If your system is designed for one material only, itis best to select the material by programming sequences listed under VIEW CHANNEL on page 2-12. The auxiliary input can then be used for other purposes.Start Input The start input is used when the DBA is configured for operation in the single measurement mode. See page 2-8 for configuration details. A material thickness measurement is initiated whenever an OFF to ON transition is seen at the start input. The measurement sequence varies depends on whether the DBA has been configured for Mode 0 ‘or Mode 1 operation. Mode 0 Sequence + Start input triggers an immediate thickness reading regardless of whether or not material is, present in front of the sensor. + The output labeled Part Present / 0 Sheet operates as a part present output. The output tums on and off based upon sensing the presence or absences of material in front of the ‘sensor. This output operates totally independent of the start input, + The 1 of 2 sheet status is latched until the next measurement. START START HANDSHAKE. prox [ZZ AN STATE panrrasn 0 sneer [7777 RROSPRORSTATE ZZ, MEASURING PULSE THe Mode 0 Operation Mode 1 Sequence ‘© The start input prepares the sensor to take a thickness reading. The thickness reading does not occur until material is detected in front of the = The output labeled Part Present / 0 Sheet operates as a 0 sheet output. This output tums (on whenever a material thickness below the 1 sheet tolerance window is measured. The term 0 sheet may be misleading since this output only tums on when a thickness measurement is taken which is initiated by material in front of the + The 0, 1 or 2 sheet output status clears when the start signal is turned off TART ‘START HANDSHAKE PROX MEASURING PULSE Part Present/ 0 SHEET 4 SHEET 2 SHEET Mode 1 operation + Ferrous input channels configured for single measurement mode operation can be configured for Mode 0 or Mode 1 sequence. + Non-Ferrous input channels configured for single measurement mode operation will operate in Mode 0 sequence only. +The start input is edge sensitive. A measurement is initiated upon seeing an off to on transition at the start Input. This input must be held on for a minimum of 30 miliseconds,Handshake Output This output reflects the state of the start input. It turns on when the start signal is received and recognized by the DBA logic. The output remains on as long as the start input is on. Itturns off when the start input is turned off. This output is @ confirmation that a start input was seen by the DBA controller. The PLC interface logic should ‘watch for this output as verification that the PLC / DBA interface is operating properly. This output can also be used to simplify the timing of the start input. Instead of timing the start input to insure the ‘minimum 20 millisecond “on” time, simply send the start signal and wait for the handshake output to verify that the start signal was recognized by the DBA. Part Present / 0 Sheet Output ‘This output operates in one of two different ways based upon how the DBA system is configured, 11. If configured for continuous measurement mode, this output turns on and off based upon material being present in front of the sensor. The presence of material is detected by a proximity switch in the face of ferrous sensors. Non-Ferrous sensors detect material presence by using their thickness sensing technology to detect material ‘approaching the sensor face. 2. If configured for single measurement mode, Mode 0 sequence, this output operates identical to continuous measurement mode as described above. 3. If configured for single measurement mode, Mode 1 sequence, this output turns on whenever a measurement indicates a material thickness that is below the 1 sheet tolerance window. The 1 sheet tolerance window is a window established by DBA logic that considers any thickness reading that is within 430% of the preset thickness value as a 1 sheet condition. This 30% figure increases slightly for preset values below .8mm. See page 2-6 for details on the tolerance window. 4 Sheet Output This output turns on whenever a thickness measurement indicates that material thickness falls within the 1 sheet tolerance window. The 1 sheet tolerance window is a window established by DBA logic that considers any thickness reading that is within +30% of the preset thickness value as a 1 sheet condition. This +30% figure increases slightly for preset values below .8mm. See page 2-6 for details on the tolerance window. 2 Sheet Output ‘This output tums on whenever a thickness measurement indicates that material thickness is greater than the 1 ‘sheet tolerance window. This is an indication that 2 or more sheets are present in front of the sensor. The 1 sheet tolerance window is a window established by DBA logic that considers any thickness reading that is within +20% of the preset thickness value as @ 1 sheet condition. This +30% figure increases slightly for preset values below ‘8mm. See page 2-6 for details on the tolerance window.Interface Logic Recommendations ‘There are numerous ways to setup the DBA and use its features. Syron recommends that the following logic sequences be incorporated in the PLC interface for a typical de-stacking application 4. Selup the DBA for single measurement mode, mode 0 operation. This allows accurate synchronization of thickness measurements with machine and material position. Measurements can also be triggered when no material is in front of the sensor for verification that a sheet has been released and to clear the previous measurement. 2. Write code to monitor the 1 sheet output and only allow the process to continue if this output turns on. Monitor the 2-Sheet output and stop the process if it turns on. A 2-Sheet output typically initiates @ “Shake” sequence to shed the extra blanks or they are discarded. If neither output tums on, an incorrect preset thickness may have been selected for the job in process. 3. Initiate @ thickness measurement immediately after releasing the sheet to verity that it has been transferred to the next position. Monitor the 1-Sheet and 2-Sheet outputs to insure that they both turn off after this ‘measurement indicating that no material is present. This also clears the resulls of the previous measurement. ‘The results of a thickness measurement are latched until the next measurement is initiated. tis important that your logic clears the previous measurement to insure that your logic does not react to the resulis of an old ‘measurement. 4. Monitor the “handshake” output to verify that the start input is received and recognized by the DBA. ‘This output must cycle ON and OFF each machine cycle to verify that new thickness measurements have been taken. Monitor this ON/OFF transition to insure that it occurs every machine cycle. ‘The "Handshake" output can also be used to control the time duration of the “Start” signal from the PLC. Hold the start signal on until the handshake output is received from the DBA. 5. Monitor the status of the "Part Present” output during thickness measurements. An accurate measurement can only be taken ifthe sensor is held against the sheet during the whole measurement. The “Part Present” output indicates that material is close enough to the sensor face for an accurate measurement. Any interruption of this output during the measurement can indicate a thickness measurement that is thinner than reality. This could result in a double sheet condition being missed by the DBA. ‘An “ON’ transition of the “Part Present” output can be used in the PLC logic that initiates a start signal to the DBA. This insures that a measurement is not initiated before the material is properly positioned. A transition in the 1-Shest or 2-Sheet output can be used to indicate that the measurement is complete and the “Part Present” output turning off is no longer a concern, 6. Many systems monitor sheet thickness as material is de-stacked and transferred to a centering station or crowder prior to the final feed into the pracess. The PLC lagic should monitor the sheet at this intermediate station to insure that two sheets aren't stacked on top of each other prior to final feed. A second DBA sensor in this station provides extra security, 7. Many systems have a PLC interface screen that is used to select system operating parameters for a job. This screen provides a field in which the single sheet thickness for that job is stored or selected by the operator. PLC logic then reads that single blank thickness and generates a binary 1 thru 12 output to select one of 12 preset memory locations in the OBA. This PLC lagic expects the material thickness stored In each memory location to match their logic expectations. ANrticiness waves ar nat preprganmed atthe fay. This memory felon / tikes value fltonp has boon cle by he jlo toy and st be coconerta hare arenes and ta pomenming dn mantenance- Pear eer tienes Yates execed by you elcon re Sup Foced n APPEND8. Use of the ‘LEARNT function will permanently change the thickness value stored in the preset memory location that is active during the "LEARN" sequence. This can cause operational problems in systems that select presets using binary input as described above. The thickness value expected by the PLC logic may have been permanently changed to a very different value if “LEARN” has been used. Systems that intend to use the "LEARN function should dedicate one of the 12 presets for use during every “LEARN’ sequence. This dedicated preset will always be used when LEARN is initiated with the understanding that the stored thickness value is randomly changed each time LEARN is used. See page 2-16 for details. 9. Use of the Sel. through Sel4 binary inputs to select thickness presets will lock the DBA keypad in the "REMOTE" mode. Keypad functions necessary for setup and maintenance of the DBA are disabled while in the “REMOTE” mode. PLC interface logic must provide the operator with a way to force these outputs off during routine setup and maintenance. (One approach is to automatically force these outputs off when the machine is in the manual mode and return control of these outputs to the PLC when in the automatic mode, ‘The DBA will show “LOCAL” on the display when these DBA inputs are off and all keypad functions are enabled, The DBA will show "REMOTE" on the display if any preset selection inputs are turned on. Many keypad functions are disabled, See pages 2-4 and 2-6 for details. Please record your approach to LOCAL mode access on the setup record in Appendix A. 40, The fauit relay is a mechanical relay that is energized when all circuitry and logic inside the DBA is functioning properly. This relay de-energizes if a fault is detected in the internal operation of the DBA. PLC logic should monitor the N.O. contact ofthis relay and use it to allow normal operation ifthe relay is energized. The machine should be stopped or a warning sent ifthe fault relay de-energizes. The DBA may not provide reliable double blank detection when this relay is de-energized indicating a fault, Optional Functions 4. Automated pallet change sequences can be initiated by DBA thickness measurements. A thickness ‘measurement taken before lifting a sheet from the stack will provide a 2-Sheet output if more than one sheet is Con the stack. The last sheet will provide 2 1-Sheet output from this measurement, which is used to initiate the pallet changing sequence. ‘This additional logic may slow system response time so you may not want to begin measurements on the stack until the bottom of the stack approaches, 2. Automated tool change or job setup sequences that disconnect the DBA sensor will result in the *Fault Relay" ‘de-energizing and a fault indication on the DBA display. The DBA remains lacked in this fault condition until the sensor is reconnected and a fault reset is initiated. The fault reset can be initiated by pressing the EXIT key or by sending a “CLEAR FAULT” (binary 15) input from the PLC. See page 5-2 for details. ‘This fault condition can be prevented by using the auxilary input as a "Fault Disable” input. The fault disable input is turned on prior to disconnecting the sensor. It is held on until the sensor is reconnected and the machine is retumed to its normal operating mode, A “D" appears on the DBA display to indicate the fault disable input is ON. See page 2-3 for details on the display. See pages 2-9 and 2-13 for details on configuring the fault input for fault disable use. See page 5-3 for other detailsChapter 6: Installation and Startup ‘This section provides typical installation and startup procedures that should be followed whenever a new system is. installed or components are changed on an existing installed system, The programming portion of this section covers all possible features that may or may not have been used by the systems integrator that developed the interface logic to the machine control PLC. Integrator Note ~ It is extremely important that you document the DBA features used and the programmed values that you selected for proper interface to the machine logic that you developed. Plant level maintenance and Syron factory service will need these details for long term maintenance of the overall system. Several steps in this section cover multiple setup choices for a specific feature, Please document the setup choices expected by your interface logic on the setup sheet provided in Appendix A. Mechanical and Electrical: 1. The DBA controller housing is oil tight (Nema 12) and is designed for use in an industrial environment. As with any piece of electronic equipment, it should be protected from excessive temperature, vibration and electrical noise generated by welders, drives, servos, etc. The electrical connectors that exit from the bottom of the controller housing require 18 inches of clearance to accommodate the installation of the connectors, the cabling ‘and their minimum bending radius. 2. The DBA sensor must be installed in a spring mount assembly as shown on page 6-4. The spring mount should be adjusted for 4mm to 6mm of spring compression when the system performs a thickness measurement, This insures that the sensor can set fiat against the sheet during measurements. A consistent flat relationship of the sensor face on the sheet is critical for reliable operation of the DBA system 3. Sensor cables should be routed away from electrical noise generating devices and should not be run in condult or cable tray that contains high voltage signals. Maximum sensor cable length should be 30 meters or less (consult factory if longer lengths are required). If the sensors are mounted on a moving structure, the sensor cables should be mechanically anchored to the structure to prevent side loading from the cable pulling at the sensor connector. 4. Sensor mounted bumpers and vacuum cups are not recommended unless absolutely necessary. See pages 6- 5 and 6-6 for details. If either of these accessories are used, they must be installed and adjusted as outlined on our installation instruction sheet. Failure to consistently follow these instructions can result in double sheets not being detected, 5. The control cable is a multiconductor cable that provides AC power to the DBA controller and carries discrete 24VDC signals between the DBA and PLC. Syron recommends using the standard § meter long control cable to a termination point with locally purchased cabling from there to the PLC if a length greater that § meters is required. The discrete signals require the same basic wiring considerations as any other 24VDC PLC interface. This cabling should be routed away from electrical noise generating devices or cabling. Voltage drop may be a concer over extreme distances between the DBA and PLC. 6. Verify that your input power to the DBA controller matches the voltage shown on the DBA controller housing.Programming / Setup 1. Program the measurement mode. The DBA can be programmed to run in the continuous or single measurement mode. See page 2-7 for details. If single measurement mode is used, you must select Mode 0 or Mode 1 operation. See page 2-9 for details. 2. Your PLC interface logic may be using the DBA auxilary input for Mode 1 / Mode 0 selection, fault disable or material selection use. See page 5-2 for details. See Appendix A where the functional use of this input should be recorded. Program the auxillary input for its intended function as described under "VIEW CHANNEL" on pages 2-9 and 2-12. 3, Program preset single sheet thickness values into preset memory locations 1 through 12. See page 2-6 for details. These values have been predetermined by the systems integrator if there is a PLC interface that allows selection of material thickness from a PLC interface screen. See Appendix A where these thickness values ‘should be recorded. New controllers ship from the factory with no values preprogrammed into the presets. 4, Calibrate the system using a sample piece of material that is close to the thickest sheet processed in the system, See page 2-16. This procedure will first establish sensor signal strength with no material at the sensor. Sensor signal strength is then established with the sample sheet. All production thickness calculations are then calculated based on these two signal strength values. Highest accuracy is achieved when production readings fall between these two calibration values. ‘Syron recommends that a small calibration sheet be kept at each pressline for use by all personnel during calibrations. This sample should be clearly marked with its actual thickness in millimeters. Calibration must be performed whenever a system is initally installed and when sensors, sensor cables, or sensor mounted bumpers and vacuum cups are replaced or adjusted. Functional Checks Recommended at Each Job Changi ‘The following procedures are not required but can catch a functional problem before damage can occur. 41. Verify that the preset thickness value shown on the DBA display is close to the actual thickness of the material being processed on the new job. You must view the thickness displayed on the DBA display, not the thickness shown on the PLC interface screen. See page 7-1 for details. The following items should be checked if these ‘two values don’t match: a, The material being processed may not be the correct thickness for this job. b, The preset thickness values held in the DBA memory may not match the values expected by the PLC Interface logic. See pages 5-6 item 7, 7-2 item 3a and Appendix A. 2. Monitor the DBA display during intial feed cycles. The thickness measured by the DBA should be close to the displayed preset value and the actual thickness of the material being processed. The following items should be checked if these values don't match: a. The sensor may not be properly adjusted in the spring mount for a proper flat contact with the material during thickness measurement. See page 7-1 item 1 for details. b. The DBA may need calibration. See page 7-3 item 4 for details. These two quick checks will insure that every new job startup is functioning properly. Operational problems can be detected and corrected before machine damage occurs.Sensor Selection, Mounting and Adjustment Sensor Catalog Numbers: ‘The ferrous sensor catalog numbers shown below have a -01 suffix to indicate the recommended ratchet style connector. The older bayonet style connector is used on ferrous sensors that do not have the -01 suffix. The non-ferrous sensor is only available with the ratchet style connector. Max catstog# | MA | Da, | single Shect - yee | Thickness DIS0242-01 FE 42mm _| 2.3mm (.09") ‘pisozsa-o1_| FE | Sdmm | 3.0mm (118°) 1S0276.01 | FE | 7emm| 46mm (18) DES1142 NF__| 42mm | 3.0mm (.118") Sensor selection must be based on the maximum single sheet thickness that will be processed. Effects of Material Properties: ‘The ferrous sensors utlize pulsed, electromagnetic fields in making their measurements. This sensor will only measure ferrous materials. The carbon content of steels may affect the accuracy of a measurement ‘The higher the carbon content, in stee! alloy. the less magnetic they appear to the sensor. This limits the ability of the sensor to magnetically saturate high carbon steels, resulting in readings that are lower than the actual thickness of the blanks. Some stainless steel alloys will behave in a similar manner. Materials such as aluminum, copper, brass and most stainless steels cannot be measured with the ferrous sensor. The non-ferrous sensor and driver are designed for these materials. Most non-ferrous materials require calibration with samples of each material being processed. Multiple material specific calibration curves can be stored in the DBA for selection each time the material is processed, Questions regarding the measurement of high carbon, magnetic stainless stee! or other materials with the DBA should be referred to Syron Engineering and Manufacturing Corp. Sensor Mounting: All DBA sensors are contact type sensors designed for direct contact with the material surface. Ferrous sensors have a stainless steel face designed for continuous impact. Some care should be taken to control extreme impact forces by isolating the sensor from the mass of the mechanism through spring sensor mounts, Flow restrictors in pneumatic sensor mounts help prevent extreme impact forces, Non-ferrous sensors have a fiberglass resin contact surface that Is somewhat more sensitive to impact and abrasion, All sensors must be mounted in such a way that the entice sensing face is able to seat FLAT on the surface of the material to be measured. Any variable air gap or imperfect contact between the sensor and the materia will result in improper thickness readings. In extreme cases, poor sensor seating may result in failure to properly detect a multiple part (double blank) condition. The following drawing shows some ‘examples of good and bad sensor seating, Sensor Seating‘Sensor Mount Adjustment The best approach is a resilient mounting scheme in which the sensor is suspended by springs as shown in the diagram below. This isolates the mass of the ‘sensor from the mass of the support structure and allows the sensor to adjust itself to the surface of the material itis measuring. Syron has developed a series of resilient mounts based on this principle. These resilient mounts employ a spring flex that allows the sensor to sit flat fn the surface of the material and absorb shock. | sev FO seNGoR Typical Syron Mount The sensor needs to be compressed between 4mm. ‘and 6mm (.16" and .24") for optimal compensation for blank distortion and flex NOTE: Syron Engineering and Manufacturing Corporation warrants the proper function of the DBA only when original Syron sensor mounting fixtures are used. Syron’s standard sensor spring mount allows 15mm (.60") of overall spring travel. Some end effector installations mount the DBA sensor next to vacuum ‘cups that have 25mm to 50mm (1.0" to 2.0") of spring travel. Syron offers extended travel spring mounts that allow 30mm (1.2") of overall spring travel. The ‘extended travel mount allows the sensor to compress ‘over the longer travel of the spring mounted cups while maintaining the required 4mm to 6mm of ‘sensor spring compression after the sheet has been lifted off the stack. Extended Travel Mount In all cases, sensor spring mount compression should not exceed 4mm to 6mm when the sheet has been lifted from the stack and thickness ‘measurements are taken, Due to the type of measurement the sensor performs, these sensors must remain stationary relative to the ‘material for the duration of the measurement. During ‘a measurement oyole, the sensor creates a magnetic field in the material directy in front of the sensor face. ‘The sensor must remain in contact with that particular spot on the material for the entire measuring cycle for an accurate measurement, Movement can also create air gaps, scratch the ‘material surface and cause sensor wear. = i =] ‘Sensor on Moving Material‘Sensor Bumper Adjustment ‘Aring shaped bumper can be mounted on the end of the sensor to reduce material scratching. Bumpers should only be use when processing “Class A” surfaces (outer body panels). The bumper will also protect the face of the sensor from hammering under certain conditions. SENSOR FLUSH WBLUPER Sensor with Bumper The bumper is mounted on the sensor as shown above. Care must be taken to accurately adjust the bumper-face to the face of the sensor. A straight ‘edge is used to align the bumper face with the sensor face. This aligned adjustment will provide material protection while maintaining the full thickness ‘measurement capabilites of the sensor. ‘The sensor face can be recessed slightly behind the bumper face for additional material surface protection and to protect the sensor face from weld splatter or other material surface imperfections. The air gap adjustment procedures shown on the bumper installation instructions must be followed by all personnel that install or adjust bumpers. These instructions will result in a .003" to .008" air gap that will still provide accurate measurements, Sensor sensitivity is decreased by this air gap so the maximum thickness measurement rating of the sensor will be decreased by 15%. Air gaps larger than .003" to .005" will drastically reduce measurement capacity and will eventually prevent the detection of double blank conditions. Asumpes shoud not be used _uniss tiscluty necessary. Mey are required, they must be hte ar sjusted exact essed on he nstalatoninatutons: ‘SeNsoR MOUNT euwrer — I STRAIGHT EDGE Bumper-Sensor Settings Care must be taken to insure that the sensor bumper does not interfere with the spring compression of the sensor spring mount. Verify that the bumper mounting fing does not come in contact with the sensor spring mount bracket during spring compression‘Sensor Vacuum Cup Adjustment ‘A vacuum cup can be mounted on the sensor to hold the material against the sensor face. ‘The vacuum cup is mounted on the sensor as shown below. Care must be taken to accurately adjust the sensor face to the cup material contact pads. A straight edge is used to align the sensor face with the cup contact pads. This aligned adjustment will pull the material against the sensor face for good thickness measurements. The sensor face can be recessed slightly behind the ccup contact pads for material surface protection and to protect the sensor face from weld splatter or other material surface imperfections. The air gap adjustment procedures shown on the vacuum cup installation instructions must be followed by all personnel that install or adjust the cup. These instructions will result in a .003" to .008" air gap that will stil provide accurate measurement. Sensor sensitivity is decreased by this air gap so the maximum thickness measurement rating of the sensor will be decreased by 15%, Air gaps larger than 003" to 005" will drastically reduce measurement capacity and will eventually prevent the detection of double blank conditions. AN sensor mounted vacuum cups can intr wrth the proper operation of te DBA system Cue ar eed, they must. Inetaee and Ssjucted orally av tad ‘on the netallaon instructions: SENSOR sTRAGHT Ese ‘Vacuum Cup ~ Sensor Settings Care must be taken to insure that the sensor cup does not interfere with the spring compression of the sensor spring mount. Verify that the cup mounting ring does not come in contact with the sensor spring ‘mount bracket during spring compression. Recommended Sensor Mount ‘This concept drawing shows a sensor mounting arrangement that will provide reliable trouble free operation, Standard vacuum cups are mounted directly adjacent to the sensor spring mount to hold the sheet flat and stationary against the face of the sensor. This flat and stationary presentation of the sheet against the sensor face typically eliminates the need for bumpers to prevent surface marring. The unobstructed view of the sensor face against the material allows visual verification that the sensor is held flat against the material during thickness measurements. oun cues 710 tiem 16 750m) ‘Sensor Mount Concept Drawingsensor cae nstaaton Syron uses a special high flex cable in all sensor cable assemblies. All cable manufactures have a minimum bend radius specification that is typically about 10 times cable diameter. Our sensor cable has been tested to over 10 million cycles with a 4 inch (100mm) bend radius. MINIMUM 4.0" (100mm) BEND RADIUS coop ‘A bend radius of less than 4° (100mm) will shorten the service life of high flex cable, cate wut BE DAMAGED. HERE BAD it Corerecror Use a right angle connector if overheard space limitations require a right angle cable exit i Install with a loop in the cable that prevents side loading on the connector as the sensor moves through a machine cycle, a v Connector Note ~ Syron originally used a bayonet type connector on the DBA sensor and sensor cables, Field experience has shown that this connector allows movement between its sockets and pins when installed in a high vibration application. This causes wear at the socketipin contact point that eventually causes loss of continuity. Operational symptoms and DBA fault displays will appear to indicate a sensor or cable failure. Replacing the sensor or cable may appear to correct the problem but may only temporarily mask the real problem by replacing a wor pin or socket while leaving the mating pin or sockel seriously damaged. Syron introduced a ratchet type connector several years ago as our standard for all new systems. This connector locks tightly together to eliminate movement between the pin and socket. Syron recommends conversion to the ratchet style connector on all new and existing applications. Existing sensors and cables can be upgraded from bayonet to ratchet at the factory.IMI TAN Sensors with the ratchet style connector have a red and blue line on the connector. The cable mounted mating connector must be threaded all of the way down to the top edge of the blue line. The red line must not be visible. The connector pins will damaged if the connectors are not completely tightened.