SCATEC-J Laser Copy Counter This product represents a precision measuring device which has been designed for the detection of objects and parts. It generates and provides measured values issued as electrical signals for following systems. User manual FLDK 110G1010/S14 FLDK 110G10/xxxxxx Rules for proper usage Installation, mounting and adjustment of this product may only be executed by skilled employees. General notes Set-up Only mounting devices and accessories specifically provided for this product may be used for installation. 2 www.baumer.com Baumer Electric AG Frauenfeld, Switzerland Unused outputs may not be connected. Unused strands of hard-wired sensors must be isolated. Do not exceed the maximum permissible bending radius of the cable. Before connecting the product electrically the system must be powered down. Where screened cables are mandatory, they have to be used in order to assure EMI protection. When assembling connectors and screened cables at customer site the screen of the cable must be linked to the connector housing via a large contact area. Unless this product has not been specifically marked it may not be used in hazardous areas. Installation Manual SCATEC-J Version 2010-04 Table of Contents FLDK 110x10/xxxxxx Check section 14 for data and information varying from the standard manual ! 9. 8. 7. 6. 5. 4. 3. 2. 1. Instructions for use Adjustments Installation Sequence of the signals Definition of technical terms Part identification Principle of operation Introduction Safety information and Certifications 10. Specifications 11. Accessories 12. Maintenance 13. Troubleshooting Baumer Electric AG Frauenfeld, Switzerland 14. Corrections for customized FLDK 110x10/xxxxxx 3 www.baumer.com 4 www.baumer.com Baumer Electric AG Frauenfeld, Switzerland Complies with 21CFR 1040.10 and 1040.11 SCATEC-J complies with the following safety standards: However, the laser should not be aimed deliberately at people. The laser beam should also be blocked at the end of its intended path. Avoid looking directly into the beam for longer periods. Brief irradiation of the eye (0.25 sec) as can occur during an accidental glance is not regarded to be dangerous. The laser diode installed in the SCATEC-J emits visible red light. This laser belongs to laser class 2 as specified by the standard IEC 60825-1 / 2001. Safety information and Certifications Manual SCATEC-J Version 2010-04 0 1 Manual SCATEC-J Version 2010-04 2 Introduction SCATEC-2 has the same key feature as all the other sensors from the SCATEC family: The capability of non-contact detection of object edges. SCATEC is the sensor of choice when it comes to detect flat objects conveyed in an overlapping stream or individually. The sensors in the SCATEC family were developed and highly optimized particularly with regard to the specific demands of non-contact counting of overlapping paper sheets and newspapers. Therefore the printing industry will be the ideal area of application for the SCATEC. Generally speaking a SCATEC sensor reacts to an edge facing the sensor’s laser beam. If the laser beam strikes such an edge, SCATEC responds with an electrical output pulse of fixed duration.The • • • • 5 www.baumer.com counts edges from a thickness of 1.5 mm optimum working distance: 40 mm “plug and play”; the user is not required to make adjustments counting rate up to 280,000 copies per hour Manual SCATEC-J Version 2010-04 Principle of operation Baumer Electric AG Frauenfeld, Switzerland Within the SCATEC family, the SCATEC-J is characterized by the following properties: 3 • • 6 www.baumer.com Baumer Electric AG Frauenfeld, Switzerland The orientation of the object to the beam is significant. An edge facing towards the beam creates a small ration v/r, in contrast to an edge facing away from the beam. Therefore only edges facing towards the laser beam will be detected! Edge detection is independent of the color, as only the ratio of the light intensities and not the absolute value is used for detection. This principle of operation clearly demonstrates that: Described simply, the SCATEC-J consists of a laser light source and two photodetectors. The beam is aimed diagonally at the objects to be detected. Photodetector R is located close to the laser light source and photodetector V in a forward sensing position. The sensor measures the ratio between signal v (light propagated forwards) and signal r (light propagated backwards). The ratio v/r differs widely depending whether the beam strikes on a flat surface or on an edge. When an edge moves into the laser beam, the direct line of sight from detector V to the point of contact of the laser is obstructed, which reduces signal v, and the edge also increases the backwards propagation, causing signal r to increase. Both effects cause ratio v/r to become substantially smaller than with a flat surface. If ration v/r falls below a specific level, the sensor interprets this as an edge. Manual SCATEC-J Version 2010-04 Part identification Front window Lower edge of sensor Alignment aid h Running direction Front edge Power-LED (green) Baumer Electric AG Frauenfeld, Switzerland Conveying plane Tail edge Edge-LED (yellow) Sensor plug 7 www.baumer.com Definition of technical terms Manual SCATEC-J Version 2010-04 4 5 d For reference, the terms defined in this section are used throughout the manual. k Beam blocker Distance between the lower edge of the sensor and the conveying plane a Mounting height h Baumer Electric AG Frauenfeld, Switzerland The edge lies on the working plane. With thick overlapping copies, the working plane is slightly higher than the top of the conveying plane on which the copies are transported. Distance d is measured vertically to the lower edge of the sensor. 8 www.baumer.com Working plane Manual SCATEC-J Version 2010-04 Working distance d Separation between two successive edges, measured along the conveying plane. (Also referred to as the object interval.) Distance between the lower edge of the sensor and the working plane. Thickness of the copy at the point where the edge is to be detected. Overlap a Edge thickness k The edge of an object facing the laser beam. Front edges are detected by the sensor. Front edge: detectable Laser beam Front edge The edge of an object facing away from the laser beam. Tail edges are not detected by the sensor unless they are pointing upwards. Tail edge: non-detectable Tail edge The preferred running direction is indicated. The opposite direction is also permitted by the SCATEC-J. Dead time Baumer Electric AG Frauenfeld, Switzerland Output pulse p t Running direction 9 www.baumer.com Dead time Sequence of the signals Manual SCATEC-J Version 2010-04 The sensor responds to an edge with an output pulse with period p. The dead time begins when the pulse is issued. The sensor can only issue the next pulse after the dead time t has expired. This means: an edge detected by the beam during the dead time does not initiate an output pulse. 6 time p t Running direction 10 www.baumer.com dead time (period: t ) Baumer Electric AG Frauenfeld, Switzerland output pulse (pulse period: p) yellow edge indicator LED The yellow edge indicator LED lights as long as the edge is located in the beam. The output pulse is issued at the end of the edge. The dead time begins when the output pulse is issued. During the dead time and when issuing the pulse, the SCATEC-J is inactive, i.e. no edges are counted. Therefore, the next output pulse can only be issued after the dead time has expired and the output pulse has been issued. on off on off on off Manual SCATEC-J Version 2010-04 7 7.1 Electrical connection Installation (2) (1) Block the laser beam after the objects whenever possible. Adjust the sensor so that the laser beam is aimed towards the edges to be counted. (When fitted correctly, the overlap of the copies is facing in the same direction as indicated in the alignment aid.) Mount the sensor at a height h of 40 mm (+5/-10 mm) with the front window parallel to the working plane. 1 h=40 mm 4 Clean window 11 www.baumer.com 2 2 5 3 +/- 3° 1 Baumer Electric AG Frauenfeld, Switzerland Beam blocker Make the electrical connection as specified in Sections 10.2 Electrical data and 10.3 Pin assignment. (3) Keep the window clean (no fingerprints). Mounting (4) 7.2 (5) A direct line of sight from the laser impact point to the entire front window must be ensured. Manual SCATEC-J Version 2010-04 Mounting height h max. +/- 3° Front edge: detectable Laser beam The copies are counted when the edge facing the laser beam moves through the beam. If an edge faces away from the beam, it is not detected. Tail edges are therefore not counted unless they face upwards. 40 mm above the conveyor belt The resolution is dependent on the distance. The highest resolution of 1.5 mm edge thickness is achieved at a distance d of 30 – 45 mm. (See also Section 10.6 Application data.) Overlap orientation The SCATEC-J permits both running directions. The edges facing the laser beam are detected by the sensor regardless of the running direction. Angular tolerance Running direction d=80 mm Baumer Electric AG Frauenfeld, Switzerland Tail edge: non-detectable Front window 12 www.baumer.com The direct line of sight from the impact point of the laser to the entire front window must not be obstructed by the mountings in a distance range d of 0 – 80 mm. If mountings or other components are close to this zone for any reason, you should consult a technician from Baumer Electric AG in this respect. Manual SCATEC-J Version 2010-04 7.3 Beam blocker Cleaning the front window Uncontrolled reflections of the laser beam can cause malfunctioning of the sensor or dazzle people. Therefore, a beam blocker should be fitted whenever possible to block the beam when there is no target present. A flat surface (at least approx. 25x25 mm) made of a matt, non-reflecting material is recommended as the beam blocker. The beam blocker must be mounted parallel to the sensor. The yellow edge indicator LED must not light when the laser beam strikes the beam blocker. 7.4 7.5 Checklist for correct fitting Fingerprints, dust and other forms of dirt on the front window can impair the function of the sensor. It is normally sufficient to wipe the glass pane dry with a clean (!), soft cloth. Alcohol may be used for heavier soiling. 13 www.baumer.com Baumer Electric AG Frauenfeld, Switzerland the green power LED lights as long as the electrical supply is connected the product overlap faces in the same direction as indicated on the sensor label the laser beam has a diameter of about 2 mm at 40 mm beneath the window the yellow edge indicator LED does not light when the laser beam strikes the beam blocker the yellow edge indicator LED lights as long as an edge is located in the beam the front windows are clean Adjustments Manual SCATEC-J Version 2010-04 • • • • • • When the SCATEC-J is fitted correctly: 8 14 www.baumer.com Baumer Electric AG Frauenfeld, Switzerland The SCATEC-J is ready for operation after fitting. No further adjustments are necessary. Manual SCATEC-J Version 2010-04 9.1 9 Maximum counting rate Instructions for use on off high low Scatec-J p Time t Running direction Output pulse Pulse length p Dead time t Yellow edge-LED Since the output pulses and the dead time cannot overlap, edges must be separated by at least a dead time. (With the SCATEC-J, the dead time t is always greater than the output pulse period p). If the following edge arrives within a time shorter than the dead time, then this edge will be suppressed meaning that the edge will not initiate an output pulse as illustrated in the figure below. Manual SCATEC-J Version 2010-04 Dead time Therefore: t = 12 ms maximum counting rate = 1/12 ms = 300,000 per hour 15 www.baumer.com Baumer Electric AG Frauenfeld, Switzerland The dead time t therefore determines the maximum counting rate because within time t, the SCATEC-J cannot issue more than one output pulse. Example: The maximum counting rate is therefore 1/t. Variation of the working distance Please note that this is the maximum counting rate. The closer the actual production rate gets to this value the higher the risk becomes that copies are suppressed due to too short intervals between copies. If suddenly the Scatec-J starts to miss copies while the production rate is run up, the reason very often are occasionally way too short intervals between copies. Such irregularities of the lap stream are very often unexpected and difficult to see directly. 9.2 the sensitivity of the sensor varies with the working distance Applications outside the paper processing industry The thickness that an edge must have to be detected by the SCATEC-J depends on the working distance. The SCATEC-J is most sensitive at a working distance of about 40 mm. The relationship between the sensitivity and the working distance is contained in the specifications in Section 10.6. 9.3 16 www.baumer.com Baumer Electric AG Frauenfeld, Switzerland Due to the fundamental principle of edge detection employed by the SCATEC-J, the field of application for the sensor is not restricted to the paper processing industry. For applications concerning high-gloss surfaces (e.g. sheet metals), it is advisable to consult a technician from Baumer Electric AG on the application. Manual SCATEC-J Version 2010-04 Laser beam LED 110 x 50 x 30 mm plastic (PA6.6) glass approx. 130 g IP 54 0°C to +50°C (non-condens ing) -20°C to +60°C 45 10% within the limits of VS +10 VDC to +30VDC (UL-Class 2) yes 17 www.baumer.com <2W 50 Operating voltage VS Limits: reverse-protected 8,5 Mechanical and thermal data 10 Specifications 10.1 13 Sensor size Housing material Front window Weight Protection class Working temperature range Storage temperature 15 30 Manual SCATEC-J Version 2010-04 Ripple VS Electrical data Power consumption M12 connector, 5-pole < 170 mA < 180 mA 10.2 Current consumption Average: Peak (after switching on) Push-pull max. 100 mA yes low Output connector Output circuit Current load: short-circuit protected Normal state: 10 ms see section 14 18 www.baumer.com Output pulse period FLDK 110G1010/S14: FLDK 110G10/xxxxxx: Manual SCATEC-J Version 2010-04 Baumer Electric AG Frauenfeld, Switzerland Baumer Electric AG Frauenfeld, Switzerland 10.3 2 5 4 3 Pin assignment 1 Output connection Manual SCATEC-J Version 2010-04 10.4 Push-pull Output Sensor Polyfuse Pin Operating voltage +VS Seriell TxD (sensor) GND (0V) Signal output +Vout Seriell RxD (sensor) assignment (on Scatec) +VS V Load +VS Current Sink Baumer Electric AG Frauenfeld, Switzerland Output connected as Current Source V Load Baumer Electric AG Frauenfeld, Switzerland max. 4.5 V GND 24 V min. 23 V VOut Output Voltage at VS = 24V VOut 24 V max. 1 V GND min. 19 V 1 2 3 4 5 19 www.baumer.com + VS Signal (1) output Pin # (4) Operating voltage (+10VDC ... +30VDC) ground +Vs 0V Signal output (3) Vout maximum 100 mA 20 www.baumer.com GND I Load Manual SCATEC-J Version 2010-04 Laser 10.5 Optical data 650 nm - 680 nm (visible red) 50 kHz 50% < 0.5 mW 2 (to IEC 60825-1 / 2001) about 120 mm beneath sensor about 2.5 mm about 2 mm Wavelength Pulse frequency Duty cycle Average power Laser class Beam diameter at emission point 40 mm beneath sensor 21 www.baumer.com 13 mm @ v = 1 m/s, or proportional to speed see section 14 2 m/s maximum (5 m/s maximum for thicker edges) Baumer Electric AG Frauenfeld, Switzerland equipped with NIR suppression filter and daylight suppression filter Focus position Optical receiver Application data Manual SCATEC-J Version 2010-04 10.6 Object speed 280,000 maximum copies/h see section 14 40 mm Minimum object spacing FLDK 110G1010/S14 FLDK 110G10/xxxxxx: Fold facing laser beam 0 to 55 mm beneath sensor Counting rate FLDK 110G1010/S14 FLDK 110G10/xxxxxx: 10 ms see section 14 Measuring range Product orientation 12 ms see section 14 Mounting height Output pulse period FLDK 110G1010/S14 FLDK 110G10/xxxxxx: at the end of the edge Baumer Electric AG Frauenfeld, Switzerland Dead time FLDK 110G1010/S14 FLDK 110G10/xxxxxx: 22 www.baumer.com Pulse issue time Manual SCATEC-J Version 2010-04 Sensitivity Manual SCATEC-J Version 2010-04 4-pin 4-pin 4-pin 4-pin 4-pin 4-pin 11 Accessories Article number Cable with plug ESW 33AH0200 ESW 33AH0500 ESW 33AH1000 Article number ESG 34AH0200 ESG 34AH0500 ESG 34AH1000 Manual SCATEC-J Version 2010-04 Cable length 0 25 35 40 FLDK 110G1010/S14 20 Working distance d [mm] 15 30 Sensitivity at speed up to 2 m/s SCATEC-J 10 typical sensitivity characteristics 5 45 50 Edges from 1.5 mm thickness and greater are detected Sensitivity is dependent on distance and speed Typical sensitivity: see diagram 3.5 3.0 2.5 2.0 1.5 1.0 55 Baumer Electric AG Frauenfeld, Switzerland Baumer Electric AG Frauenfeld, Switzerland An edge with thickness k (*) at distance d can be detected when in the graphics k is above the curve at the corresponding distance d. (*) Test object: cleanly cut white cardboard 23 www.baumer.com 24 www.baumer.com 2m PUR/halogen-free 5m PUR/halogen-free 10m PUR/halogen-free Cable length 2m PUR/halogen-free 5m PUR/halogen-free 10m PUR/halogen-free Edge thickness k [mm] 12 Maintenance The SCATEC-J requires no maintenance apart from keeping the front windows clean. Dust or fingerprints can impair the sensor function. It is normally sufficient to wipe the windows dry with a clean (!), soft cloth. Alcohol may be used for heavy soiling. 13 Troubleshooting Baumer Electric AG Frauenfeld, Switzerland Increase the overlap spacing or reduce the conveying speed Corrective actions Prevent faulty points on the copies Set the distance of the copies in a range where the sensor is sufficiently sensitive to detect the copies. See chart 10.6 Prevent complete coverage of the copies a) Overlap spacing sporadically too small b) Copies to close to or too far away from the Scatec, so that the copies are in a distance range at which the sensitivity of the sensor is inadequate c) Some copies are covered by another copy b) Laser beam on beam blocker causes spurious pulses c) Unblocked laser beam is reflected and causes spurious pulses 26 www.baumer.com Baumer Electric AG Frauenfeld, Switzerland Adjust beam blocker correctly (yellow edge LED must never light when the laser beam strikes the beam blocker) Install beam blocker at proper distance Apart from the edges, there are other points on the copies which cause spurious pulses Possible causes 25 www.baumer.com What is the type designation and P-code of the sensor? Exact description of the problem. (Does the SCATEC count more or less copies than actually pass the sensor?) Retain several samples of the products causing the counting error. (Mark the running direction on one sample and the approximate line along which it passes the laser beam.) If possible, digital images of the installed sensor in operation and the immediate surroundings. First try to resolve the problem using the following table. If this is unsuccessful, consult Baumer Electric AG (www.baumer.com) for technical support. The search for fault causes can be substantially shortened if the following issues are clarified before you make contact with a technician from Baumer Electric AG: 1. 2. 3. 4. Scatec counts more copies than actually pass the sensor Scatec counts less copies than actually pass the sensor Fault Manual SCATEC-J Version 2010-04 1 2 Manual SCATEC-J Version 2010-04 28 www.baumer.com 27 www.baumer.com 14 Corrections for customized FLDK 110x10/xxxxxx Manual SCATEC-J Version 2010-04 Manual SCATEC-J Version 2010-04 Baumer Electric AG Frauenfeld, Switzerland Baumer Electric AG Frauenfeld, Switzerland Manual SCATEC-J Version 2010-04 Denmark Baumer A/S DK-8210 Aarhus V Phone +45 (0)8931 7611 Italy Baumer Italia S.r.l. IT-20090 Assago, MI Phone +39 (0)245 70 60 65 United Kingdom Baumer Ltd. GB-Watchfield, Swindon, SN6 8TZ Phone +44 (0)1793 783 839 China Baumer (China) Co., Ltd. CN-201612 Shanghai Phone +86 (0)21 6768 7095 Technical data subject to change Manual Scatec-J Version 2010-04 www.baumer.com/worldwide 29 www.baumer.com France Baumer SAS FR-74250 Fillinges Phone +33 (0)450 392 466 Sweden Baumer A/S SE-56122 Huskvarna Phone +46 (0)36 13 94 30 Canada Baumer Inc. CA-Burlington, ON L7M 4B9 Phone +1 (1)905 335-8444 India Baumer India Private Limited IN-411038 Pune Phone +91 20 2528 6833 Brasil Baumer do Brasil Ltda BR-04726-001 São Paulo-Capital Phone +55 11 56410204 Baumer Electric AG Frauenfeld, Switzerland No. 10153365 Germany/Austria Baumer GmbH DE-61169 Friedberg Phone +49 (0)6031 60 07 0 Switzerland Baumer Electric AG CH-8501 Frauenfeld Phone +41 (0)52 728 1122 USA Baumer Ltd. US-Southington , CT 06489 Phone +1 (1)860 621-2121 Singapore Baumer (Singapore) Pte. Ltd. SG-339412 Singapore Phone +65 6396 4131 Printed in Switzerland