DOUBLE BLANK DETECTOR

Installation and User’s Manual

Covering the following versions:

DBD1001, DBD1002, DBD1003

©Copyright 1993-1998 Syron Engineering and Manufacturing, LLC

ALL TECHNICAL DATA SUBJECT TO CHANGE WITHOUT NOTICE

Drawing #00035MN

Revision History:
-Rev: REL 12-14-93 ECN #20317
-Rev: 001 07-01-98 ECN #22419

Engineering & Manufacturing, LLC

® 1325 Woodland Drive, Saline, Michigan 48176-1285
Telephone: 734/429-4989 Telefax: 734/429-7764
 Table of Contents

Chapter 1: Overall System 1-1

Features ............................................................................................................. 1-2

Presets ........................................................................................................ 1-2

Learn Function ............................................................................................ 1-2

Sensor Recognition ..................................................................................... 1-2

Fault Indication ............................................................................................ 1-2

Data Retention ............................................................................................ 1-2

Terms and Definitions ......................................................................................... 1-3

Chapter 2: Using the DBD 2-1

Front Panel Overview ......................................................................................... 2-2

The Display ................................................................................................. 2-2

Part Present ......................................................................................... 2-2

Parts .................................................................................................... 2-3

Thickness ............................................................................................. 2-3

The Keypad ................................................................................................. 2-3

Presets ............................................................................................................... 2-5

Entering Preset Values ............................................................................... 2-5

Measuring .......................................................................................................... 2-6

Sensor Information ...................................................................................... 2-6

Learn Function ............................................................................................ 2-6

Inhibiting the Measuring Cycle .................................................................... 2-7

Chapter 3: Trouble Shooting 3-1

F-01: Incompatible Sensor Type ................................................................ 3-1

F-02: 36 Volt Power Supply Fault ............................................................... 3-1

F-03: 5 Volt Power Supply Fault ................................................................. 3-1

F-04: Time-out Fault ................................................................................... 3-2

F-05: No Signal From Sensor ..................................................................... 3-2

F-06: Preset too Large ............................................................................... 3-2

F-07: Sensor or Sensor Cable Fault ........................................................... 3-3

F-08: No Metal Under Sensor in “Learn Mode” .......................................... 3-3

F-09: Over Temperature ............................................................................. 3-3

F-10: Missing Sensor ................................................................................. 3-3

F-12 through F-17: IIC Faults ..................................................................... 3-3

“L LC”: Control is in the “Learn Mode” ........................................................ 3-3

Blank Display .............................................................................................. 3-4

Part Present Indicator Always On ............................................................... 3-4

Chapter 4: Maintenance 4-1

Replacing Sensors ...................................................................................... 4-1

Replacing Sensor Cables ............................................................................ 4-1

Replacing the Fuse on the Driver Board Assembly

(Early versions of DBD only) ....................................................................... 4-1

Replacing the Driver Board Assembly ......................................................... 4-3

Chapter 5: Installation 5-1

Location ...................................................................................................... 5-1

Space Requirements ................................................................................... 5-1

Power Requirements ................................................................................... 5-1

Interface Requirements ............................................................................... 5-1

Chapter 6: Selecting the Proper Sensor 6-1

Sensing Range ........................................................................................... 6-1

Maximum Single Blank Thickness ............................................................... 6-1

Minimum Single Blank Thickness ................................................................ 6-2

Effects of Material Properties ...................................................................... 6-2

Chapter 7: Sensor Mounting Considerations 7-1

Sensor Mounts ............................................................................................ 7-1

Appendix A: Dimensional Information A-1

Housing Dimensions ......................................................................................... A-2

Mounting Dimensions ........................................................................................ A-3

Sensor Dimensions ........................................................................................... A-4

Appendix B: Wiring Information B-1

Wiring Information ............................................................................................. B-2

Chapter 1:
Overall System

The Syron Double Blank Detector (DBD) is The part present output indicates the
a device designed to indicate the presence presence of a part. For a measured result
of multiple sheets of ferrous material. Its below the lower limit, neither the 1 part nor
main application is for die protection in the 2 part output relay will be set. For a
stamping operations. thickness between the lower and upper
limits, the 1 part output relay is set. For a
The DBD consists of a main control unit and thickness above the upper limit, the 2 part
sensor. There is a cable for the sensor, and output relay is set.
a single cable for power and control signals
as shown in Figure 1-1.

Several sensors are available for sensing

different thickness ranges.

The sensor will detect the presence of a part

and automatically start a measurement of
part thickness. The measured result is
compared with the upper and lower limits.

Figure 1-1

The operator communicates with the unit

through an LED display and a simple 6
button keypad. Most functions require only
a few key presses to obtain selection.

1-1
Features

Presets Fault Indication

The PRESET is a reference value used by In addition to internal relays that change
the DBD to determine the number of parts state in response to the number of parts
(blanks) present, based on the thickness (blanks) detected, the DBD also has an
measured by the sensor. internal relay that opens whenever an
internal fault (with the control, sensor, or
The PRESET value is equal to the thickness sensor cable) is detected. This relay can
(in millimeters) of a single part (blank). For alert an external Die Protection Control or
example, if the part being measured is PLC of a fault condition, which can halt the
1.0mm thick, then the PRESET is entered manufacturing process, preventing damage
as 1.0mm. to the machine.

This preset value is compared with the Additionally, FAULT CODES are displayed
measured thickness. If the thickness is relating to the specific fault condition to
below 70% (60% for presets less than assist in trouble shooting. Each unit is
.7mm) of the preset value, the result is supplied with a self adhesive label that
displayed as 0 sheets. If the thickness is briefly explains each of the FAULT CODES.
between 70% and 130% (60% and 140% for This label can be placed at any convenient
presets less than .7mm) of the preset value, location, to assist the operators.
the result is displayed as 1 sheet. If the
thickness is above 130% (140% for presets The fault relay is also de-energized during
less than .7mm) of the preset value, the the learn function since normal
result is displayed as 2 sheets. measurement cycles do not begin again
until the learn function is completed. Since
The DBD stores one PRESET at a time in it is possible to start the learn function at the
non-volatile memory. keypad without completing it, the fault relay
indicates the DBD is not ready to make a
measurement.
Learn Function

If the thickness of a part (blank) is unknown, Data Retention

the LEARN (or "TEACH-IN") function can be
used to automatically set the PRESET All information entered by an operator is
value. Using the LEARN function, the DBD stored in non-volatile memory until
measures the part (blank) in question, and overwritten. Data will not be lost, even if
sets the PRESET to the thickness measured power is interrupted or the control turned off.
by the DBD. When used, the LEARN Expected retention life is 10 years.
function will overwrite the existing PRESET
value.

Sensor Recognition

All Syron sensors used with the DBD are

internally coded, allowing the DBD to
determine which sensor is connected to it.
Pressing the SENSOR key will cause the
DBD to display an "S" followed by the
sensor diameter in millimeters.

1-2
Terms and Definitions

DBD - Double Blank Detector. Part - The material being measured by the
DBD. This is the same as "blank" or
"sheet".
Blank - The material being measured by the
DBD. This is the same as "part" or "sheet".
PLC - Programmable Logic Controller.
Used to control automated machinery.
Metric Conversion - To convert inches to
millimeters, multiply by 25.4. To convert
millimeters to inches, multiply by 0.04. Sheet - The material being measured by the
DBD. This is the same as "blank" or "part".

1-3
Chapter 2:
Using the DBD

This section of the manual covers the daily The only difference between them is the
operation of the Double Blank Detector supply voltage required for each model. All
(DBD). The three models (DBD1001, are single channel detectors and control
DBD1002, DBD1003) all have the same only one sensor each.
functions and operate in the same manner.

2-1
Front Panel Overview

Figure 2-1

The front panel for the DBD is shown in

Figure 2-1. The two main features of the Part Present
front panel are the display and the keypad.
When a part is detected by the sensor, an
The display is the visual interface to the LED will be lit in the upper left corner of the
DBD. display, as shown in Figure 2-2. When
there is no part under the sensor, the LED is
It normally shows complete information from unlit.
a measurement, but it is also used to display
fault codes.

The keypad is the operator interface to the

DBD. It is used to execute functions, adjust
presets, or clear faults.

The Display
Figure 2-2
The DBD will display information as shown
in figure 2-2. The part present indicator is lit
only when the sensor is in contact with a
part (blank). Note that the display is divided
into three sections: PART PRESENT,
PARTS and THICKNESS.

2-2
Parts has been installed. Sensors are available in
42mm, 54mm and 75mm diameters. Larger
The number of parts (blanks) detected by sensors can measure thicker sheets.
the sensor is displayed as 0, 1 or 2, (as
shown in Figure 2-3) while the sensor is in
contact with part (blank). The DBD
determines how many parts are present by
comparing the measured thickness to the
PRESET value. Parts will display 0 when
no part is present. After a fault condition has been corrected,
pressing the CLEAR key will reset the
control and clear the display. If there is
another fault, or if the initial fault was not
corrected, the fault code will reappear on the
display.

Figure 2-3
The preset key allows the operator to either
"see" the currently selected preset value in
Thickness memory or to manually change the preset
value. The preset value is changed by
The measured thickness is displayed in holding down the preset key while pressing
millimeters, as shown in Figure 2-4, while either of the arrow keys.
the sensor is in contact with the part (blank).
Thickness will display 0.0 when no part is
present.

Pressing this key activates the LEARN or

"TEACH-IN" function. This function can be
used to automatically set the PRESET value
if the thickness of a part (blank) is unknown.
Using the LEARN function, the DBD
measures the part (blank) in question,
setting the PRESET to the thickness
Figure 2-4
measured by the DBD. When used, the
LEARN function replaces the existing
PRESET value.
The Keypad
Use of the LEARN function is described in
more detail on page 2-7.

Pressing this key causes the LED that

normally displays the number of parts, to
display an "S" (for sensor) and the diameter
of the sensor attached to the DBD to be
displayed where the part thickness is
normally displayed. This feature allows the
operator to confirm that the correct sensor

2-3
This key is used with the PRESET key to This key is used with the PRESET key to
increase value (thickness). decrease the preset value (thickness).

2-4
Presets

The PRESET is a value that is used by the Once entered, the PRESET is stored until
DBD to determine how may parts the sensor changed by the operator. The PRESET will
is currently measuring. The preset value is not be lost, even if power is interrupted or
entered by the operator and is equal to the the control turned off. The expected
thickness (in millimeters) of a single part retention life is 10 years.
(sheet). For example, if the part being
measured is 1.0mm thick, then the preset
should be set for 1.0mm. Entering Preset Values

When a measurement is taken, that The PRESET value (thickness) can only be
thickness value is compared to the preset entered from the keypad on the front of the
value. If the thickness is less than or equal DBD. To enter a preset value, press and
to 70% (60% for presets less than .7mm) of hold down the PRESET key and then press
the preset value (the preset value multiplied the ARROW keys to increase or decrease
by 0.7), it is considered to be a "0" sheet the value. The PRESET value will be
condition. A "0" sheet condition means that displayed as long as the PRESET key is
either the sensor measured a part or that held down. If either of the ARROW keys are
was thinner than expected. held down (while the PRESET key is also
held down) the values will increase or
If the thickness is between 70% and 130% decrease continuously. Once the desired
(60% and 140% for presets less than .7mm) value is displayed, release the keys and that
of the PRESET value, it is considered a "1" value will automatically be stored and the
blank condition. display will return to its normal operating
mode.
If the thickness is greater than or equal to
130% (140% for presets less than .7mm)
(the PRESET multiplied by 1.3) of the preset
value, it is considered a "2" sheet condition.
This is also known as "double blank"
condition and indicates that the unit has
measured a part thickness that is equal to 2
or more parts.

2-5
Measuring

Whenever the sensor is in contact with a Thickness

part (blank), the DBD takes a measurement Catalog # Diameter Range
approximately 3 times a second, or at a rate
of 3 Hz. DIS0236 36mm 0.2 - 2mm
(0.080")
If the sensor stays on the same part for DIS0242 42mm 0.2 - 3mm
more that 1 minute, the DBD reduces the (0.120")
measurement rate to 1 Hz to help prevent
the sensor from overheating. If the sensor DIS0254 54mm 0.2 - 4mm
does overheat, the thickness readings will (0.160")
begin to vary. Keeping the sensor cool DIS0275 75mm 0.2 - 6mm
assures consistent measuring accuracy and (0.240")
increases the life span of the sensor. The
measurement rate automatically returns to 3
Hz once the sensor is lifted from the part. When the DBD is powered up it "reads" the
sensor code to determine which sensor type
When the sensor is removed from the part, is installed. The unit then automatically
the display returns to zero and the output adjusts itself for that sensor type. This is
relays are deenergized. important because the accuracy of the
thickness measurements depend on the
DBD knowing which sensor is installed.
Sensor Information
Note: If the sensor is changed to a
Pushing the SENSOR key causes the LED different size, for example a 42mm to a
that normally displays the number of parts to 54mm, press the CLEAR key so that the
display an "S" (for sensor) and the diameter unit can adjust itself to the new sensor.
of the sensor attached to the DBD is shown
where the part thickness is normally
displayed. This feature allows the operator Learn Function
to confirm that the correct sensor has been
installed. Sensors are available in 42mm,
54mm and 75mm diameters. Larger
diameter sensors can measure thicker
sheets.

The 36mm sensor is no longer available for

new installations.
Figure 2-5
The thickness range indicates the range of
measurement. For double blank detection,
the thickest useable range will be 70% of
This feature allows the operator to set a
the thickness range.
PRESET value without having to know the
actual part thickness. The LEARN function
causes the DBD to measure the thickness of
the part and store that thickness as the new
PRESET value.

2-6
To "learn" a PRESET value, first press the Inhibiting the Measuring Cycle
LEARN key. The display appears as shown
in Figure 2-5. The flashing "L" in the "parts" There are applications that require the
window confirms that the control is in the measuring process to be interrupted, to
LEARN mode. The letters LC in the avoid incorrect results.
"thickness" window are a visual aid to
remind the operator to either bring a single Terminals 4 and 5 of terminal strip P2 are
sheet of the material in contact with the face used for this application. If these terminals
of the sensor and press the LEARN key are connected together, no measurement
again, or to press the CLEAR key to return will be made. The resulting output is held
to the previous settings. If the LEARN key until the sensor is removed from the part.
is pressed accidentally, pressing the CLEAR The open circuit voltage is about 30VDC.
key will return the unit to normal operation Terminal 5 is connected to earth ground.
with the original settings unchanged. The measure pulses to the sensor start
immediately after release of the inhibit.
It is important that the sensor face sit flat
against the surface of the material in order This feature is available for DBD units after
to get an accurate measurement. Any gap Jan 1996 with software version 2.0 or
between the sensor face and the material higher. Contact Syron for further details.
will result in inaccurate measurements.
Please refer to Chapter 6 for more
information on sensor applications.

2-7
Chapter 3:
Trouble Shooting

Whenever the DBD detects a problem with F-02: 36 Volt Power Supply Fault
the sensor, sensor cable, or the control itself
it will alert the operator by displaying a Possible causes:
FAULT CODE in place of the measurement • 1. The control checked the
on the FRONT PANEL. FAULT CODES supply voltage before it was up to
consist of a flashing "F" followed by a two its full value.
digit code. Simultaneously, the FAULT • 2. The 36 volt supply is
RELAY opens to alert the PLC or other defective.
remote die protection device, of the fault
condition. This FAULT CODE will be displayed after
power-up if the internal +36 volt power
By matching the FAULT CODE displayed on supply is not supplying the full 36 volts.
the control to the corrective action
suggested in this section, faults can be Turn the power to the control "off" and then
quickly diagnosed and resolved. "on" again. If the fault message does not
reappear, it may have been that the DBD
The following FAULT CODES are displayed checked the supply voltage before it was up
automatically whenever a fault condition is to its full value.
detected.
If the fault code does reappear, press the
CLEAR key to clear the display, then try
F-01: Incompatible Sensor Type making a thickness measurement. If the
FAULT CODE reappears, then the driver
Possible causes: board assembly, which contains the 36 volt
• 1. Use of a sensor not supply, must be replaced or returned for
specified for this control. repair.
• 2. Sensor cable damaged.
• 3. Sensor cable mis-wired.
• 4. Defective sensor. F-03: 5 Volt Power Supply Fault

If a sensor not designed for use by this Possible causes:

control is connected to it, the DBD will not • 1. The control checked the
operate. supply voltage before it was up to
its full value.
Check that the wires from the sensor cable • 2. The 5 volt supply is defective.
are attached to the control in the proper
order (see appendix B-1 for wiring This FAULT CODE will be displayed after
information). Mis-wired cables could power-up if the internal +5 volt power supply
prevent the control from correctly decoding is not supplying the full 5 volts.
the sensor type and size.
Cycle the power to the control and see if the
fault message reappears. If it does not,
then it may have been that the DBD
checked the supply voltage before it was up
to its full value.

3-1
If the fault message reappears, press the F-06: Preset too Large
CLEAR key, to clear the display and let the
control warm-up for a few minutes. If the Possible causes:
voltage falls below 4.5 volts, the driver board • 1. Preset is too large.
will attempt to reset itself. Press the CLEAR • 2. The control does not know
key again and then try making a thickness which sensor size is attached to it.
measurement. If the FAULT CODE
reappears, then the driver board assembly, If the PRESET value has been set too large
which contains the 5 volt supply, must be for the sensor to detect a 2 sheet condition,
replaced or returned for repair. this fault code will be displayed. See Page
7-2 for the maximum preset values for each
sensor.
F-04: Time-out Fault
If the thickness of a single sheet is close to
Possible causes: the maximum range of the sensor it cannot
• 1. Damaged or otherwise reliably detect the presence of multiple
defective sensor. sheets.
• 2. Damaged sensor cable.
• 3. Low voltage on the 36 volt To detect the presence of 2 or more sheets
power supply. at the sensor, the DBD multiplies the
PRESET value (thickness) by 1.3 (130%) in
If a measurement cycle is not completed order to develop a 2 sheet threshold.
within the time allotted by the control, this Therefore, the maximum preset that can be
FAULT CODE will be displayed. used for a given sensor is its maximum
sensing range divided by 1.3.
First try replacing the sensor. When the
sensor has been replaced, press the Multiply the preset thickness by 1.3. If the
CLEAR key and take another measurement. thickness you calculate is larger than the
If the FAULT CODE reappears, try replacing maximum thickness limit of the sensor, the
the cable and then taking another PRESET is too large. Remove any sheets
measurement after pressing the CLEAR that are in contact with the sensor, then
key. If the fault reappears again, then the press the CLEAR key to clear the fault.
driver board assembly must be replaced or Decrease the PRESET thickness by editing
returned for repair. the PRESET value.

If the PRESET is not too large for the

F-05: No Signal From Sensor sensor, then the DBD might not know what
sensor is connected to it. Push the
Possible causes: SENSOR key to confirm that it is the correct
• 1. Damaged or otherwise sensor. Check that the wires from the
defective sensor. sensor cable are attached to the control in
• 2. Damaged sensor cable. the proper order (see appendix B-1 for
wiring information). Mis-wired cables could
If there is a break between the sensor and prevent the control from correctly decoding
the control, this FAULT CODE will be the sensor type and size.
displayed.

First try replacing the sensor. When the

sensor has been replaced, press the
CLEAR key and take another measurement.
If the FAULT CODE reappears, try replacing
the cable and then taking another
measurement after pressing the CLEAR
key.

3-2
F-07: Sensor or Sensor Cable Fault F-10: Missing Sensor

Possible causes: Possible causes:

• 1. Damaged or missing sensor • 1. Damaged or missing sensor
• 2. Damaged or missing sensor • 2. Damaged or missing sensor
cable. cable.

If a measurement was started with a If the control does not detect that a sensor is
defective sensor or sensor cable, this fault attached to it, this FAULT CODE will
code will appear. appear.
Replace the sensor and cycle the power to
Replace the sensor and press the CLEAR the control. If the fault reappears, nothing
key. Try another measurement. If the fault was wrong with the sensor. Replace the
reappears, nothing was wrong with the sensor cable.
sensor. Replace the sensor cable.

F-12 through F-17: IIC Faults

F-08: No Metal Under Sensor in "Learn
Mode" These are internal communication faults.
Try pressing the CLEAR key. If the fault
Repeat the procedure for the LEARN mode, remains, power the DBD down then apply
with the sensor in contact with a single power again. If the fault persists, return the
sheet of material, when appropriate. DBD for repair.

F-09: Over Temperature "L LC": Control is in the "Learn Mode"

Possible causes: This message is a visual aid to remind the

• 1. Ambient temperature is operator to either bring a single blank of the
too high. material to be measured in contact with the
face of the sensor and press the LEARN key
If the circuit that drives the sensor again, or to press the CLEAR key to return
overheats, the control will display this to the previous settings. If the LEARN key
FAULT CODE. was pressed accidentally, pressing CLEAR
key will return the unit to normal operation
If the DBD is operated inside a control with the original settings unchanged.
cabinet with a high ambient temperature and
insufficient ventilation, the circuits may
overheat. If this fault occurs let the control
cool off without power for 10-15 minutes and
try it again. If the fault reoccurs and high
ambient temperatures have been ruled out,
then the circuit board should be replaced or
returned for repair.

3-3
Blank Display Part Present Indicator Always On

Possible causes: Possible causes:

• 1. No power to the control. • 1. Shorted proximity switch in
• 2. Fuse on driver board the sensor.
blown. • 2. The proximity switch wires in
• 3. Power supply on driver the cable are shorted
board is defective. together.
• 4. Internal IIC Cable
disconnected or Replace the sensor and then press the
installed incorrectly. CLEAR key. If the problem persists, replace
• 5. Internal Power Cable the sensor cable and then press the CLEAR
disconnected. key.

Make certain that power is being supplied to

the control. If it is getting power, remove the
power and check the fuse on the driver
board. Refer to Chapter 4 of this manual for
the location of these components.

3-4
Chapter 4:
Maintenance

The DBD requires very little maintenance. Replacing the Fuse on the Driver Board
Should something go wrong with the DBD, Assembly (Early versions of DBD only)
parts can be replaced quickly.
1. Turn power to the DBD off.
NOTE: The 24V DBD has a solid state fuse
Replacing Sensors in this location. If it does not reset
itself, there is a major fault and the
1. Turn the power to the DBD off. board needs to be replaced.

2. Disconnect the sensor from its 2. As shown in Figure 4-2, access to the
cable. driver board assembly is achieved by
removing the 4 screws that hold the
3. Connect the new sensor to the Display Board Assembly in place.
cable. Disconnect the IIC, Internal Sensor,
Internal Power, and Keypad cables. In
4. Turn the power to the DBD back most cases, the Display Board assembly
on. can be lifted out of the way without
disconnecting the control and sensor
cables.
Replacing Sensor Cables
3. Remove the old fuse. See Figure 4-1 for
1. Turn the power to the DBD off. the location of the fuse.

2. Open the enclosure by lifting the 2

latches at the bottom corners and
swinging the wire clamps out of
the way. FUSE

3. Disconnect the sensor from its R42

D16
cable and the cable from the D17

DBD. MOV1
R43
P2
1

4. Connect the new sensor cable. U10

CONTROL CABLE
5. Turn the power to the DBD back CONNECTION

on.
C20

P3
1

R36
R37 SENSOR CABLE
R38
CONNECTION

Figure 4-1

4-1
4. Be certain to replace the fuse with the ∗ The DBD-1001 has a self resetting fuse
proper type as shown in Table 4-3. that is not replaceable.

Model Voltage Fuse 6. When reinstalling the Display Board

Assembly, make certain that all of the
DBD1001 24VDC NONE ∗ connectors are reinstalled such that pin 1
DBD1002 120VAC MDA-1A on the connector is aligned with pin 1 on
60Hz mating plug.

DBD1003 220VAC MDA-1/2A

50Hz

Table 4-3

Figure 4-2

4-2
Replacing the Driver Board Assembly

1. Turn power to the DBD off.

2. Open the enclosure by lifting the 2 latches

at the bottom corners and swinging the
wire clamps out of the way.

3. As shown in Figure 4-2, access to the

driver board assembly is achieved by
removing the 4 screws that hold the
Display Board Assembly in place.
Disconnect the IIC, Internal Sensor, Figure 4-4
Internal Power and Keypad cables.
Disconnect the control and sensor cables
and remove the Display Board Assembly. 7. Reinstall the PC Board Assemblies by
following these steps in reverse order.
4. Remove the four Hex Stand-offs to release Make certain that all of the connectors are
the Driver Board Assembly from the reinstalled such that pin 1 on the
Stand-off Plate. connector mates with pin 1 on mating plug
and that the locking tabs are engaged.
5. Place the old Driver Board Assembly in the
anti-static bag that the new assembly was 8. Remount the control and reattach the
shipped in. Mark the bag to indicate that it Sensor and Control cables.
contains a defective assembly and if
possible give a brief explanation of what
the problem is and send it back to Syron
for repair.

6. Before installing the new Driver Board

Assembly, it is important that the address
switches (see Figures 4-3 and 4-4) are all
set to 1 (all in the closed position).

SWITCH

Figure 4-3

4-3
Chapter 5:
Installation

This section covers the installation of the Power Requirements

DBD; the mounting and power requirements;
the cabling; and the output signals. Important! Check the nameplate on the
underside of the control to make certain that
the correct supply voltage has been provided.
Location The label is located near the entrance of the
Sensor and Control Cables (see Figure 5-1).
The DBD housing is NEMA 4X rated (IP66)
and is intended for use in an industrial
environment. As is true with any piece of The DBD comes pre-wired as follows:
electronic equipment, the DBD should be • DBD1001 for 24VDC
protected as much as possible from • DBD1002 for 120VAC 60Hz
excessive temperatures (below 0°C or above • DBD1003 for 220VAC 50Hz.
50°C), chemicals, lubricants, and vibration.

Typically, the DBD would be mounted on a

de-stacker or in a control cabinet near the
location of its sensors.

Syron Engineering and Manufacturing Corp.

manufactures sensor cables for the Double
Blank Detector in lengths up to 20 meters (65
feet). The cables ability to accurately carry
signals and power decreases as cable
lengths increase. For this reason, Syron
cautions that the system accuracy and /or
operation may be degraded when sensor
Figure 5-1
cables exceeding 30 meters (98 feet) in
length are used.
Connecting the wrong supply voltage can
severely damage the control.
Space Requirements

As shown in appendix A1 the DBD is 216mm

Interface Requirements
(8.5") by 165mm (6.5") overall and is
mounted from the front using the mounting
The DBD has 4, "form C" relay contacts
feet provided. It is recommended that an
which can be used provide signals to a Die
additional area, approximately the same size
Protection Control or a PLC. The contacts
as the DBD be provided directly below the
are rated at 10 Amps @ 250VAC or 30VDC.
control to allow room for the Sensor and
The relay outputs correspond to the "Part
Control cables. This space ensures that
Present", "Single Blank (Part)", "Double Blank
there is sufficient room for the minimum
(Part)" and "System Fault" conditions as
bending radius of the cables.
indicated on the LED display.

5-1
When the system is fully operational, the N.O. This can be used to signal the Die Protection
(normally open) contact of the FAULT RELAY Control or a PLC to take appropriate action.
will be closed. If a problem with the sensor,
sensor cable, or the control itself is detected,
the FAULT RELAY will change state, opening
the N.O. (normally open) contact.

5-2
Chapter 6:
Selecting the Proper Sensor

Sensing Range capability (in this case its maximum range) to

the control.
There are three different sensors available for For example, if a 3mm blank were measured
use with the DBD. Which model to use by a 42mm sensor (DIS-0242) the control
depends on the thickness of the material to would display a reading of approximately
be measured. Physically, the sensors differ 3mm (its maximum limit). If a second blank
in their diameters. The larger the diameter, were placed on top of the first blank, the
the greater the maximum thickness that control would still display a reading of
sensor can measure. Table 6-1 shows the approximately 3mm, even though the
maximum thickness range for a given sensor. thickness has doubled. When the maximum
limit of the sensor is exceeded, it will report a
measurement approximately equal to the
Thickness maximum limit of that sensor.
Catalog # Diameter Range
DIS0242 42mm 0.1 - 3mm Maximum Single Blank Thickness
(0.120")
DIS0254 54mm 0.1 - 4mm In order to select the proper sensor, the
(0.160") operator must first determine the maximum
single blank thickness used with the
DIS0275 75mm 0.1 - 6mm equipment. For example, if this DBD is used
(0.240") on a press that produces a number of parts,
with blank thicknesses ranging from 0.8mm
Table 6-1 to 2.3mm, then 2.3mm is the maximum blank
thickness. As stated earlier, the DBD must
be able to measure a total thickness greater
NOTE: Although the DBD sensors can than that of a single blank.
measure sheets down to 0.1mm, the
minimum sheet thickness for reliable double The threshold for determining double blanks
blank detection is 0.6mm. is set at 130% of the PRESET value. Any
measurement that is greater than 130% of
the PRESET is reported as a double blank.
These values represent the maximum Conversely, any blank that is measured as
thickness that these sensors are capable of less than 130% of the PRESET value, but
measuring, not the maximum single blank greater than 70%, is reported as a single
thickness that should be used with that blank.
sensor. In order to detect a double blank
condition, the DBD and sensor must be Any sheet that measures less than 70% of
capable of measuring thicknesses greater the PRESET value is reported as a 0 (zero)
than that of a single blank. sheet.

If a sensor is placed on a part (or sheets),

whose total thickness exceeds the maximum
range of that sensor, it will make a
measurement. However, if the total thickness
is greater than the maximum range of that
sensor, it can only report a reading within its

6-1
Knowing the maximum thickness limit of the Effects of Material Properties
sensors, and the maximum single blank
thickness, the proper sensor to use in a given These sensors utilize pulsed, magnetic fields
application can now be determined by in making their measurements. For this
dividing the maximum thickness limit of the reason, this system will only measure ferrous
sensor by 1.3. This calculation determines materials. Materials such as aluminum,
the Maximum Single Blank Thickness for a copper, brass and most stainless steels
given sensor as shown in Table 6-2. cannot be measured with this system.

The carbon content of steels will also affect

Sensor Maximum Maximum the accuracy of a measurements made with
Diameter Measurement Single this system. The higher the carbon content,
in a steel alloy, the less magnetic they appear
42mm 3.0mm 2.3mm to the sensor. This limits the ability of the
54mm 4.0mm 3.0mm sensor to magnetically saturate high carbon
steels, therefore the readings will be lower
75mm 6.0mm 4.6mm than the actual thickness of the blanks.
Some stainless steel alloys will behave in a
Table 6-2 similar manner.

If these materials are used, use of the

Minimum Single Blank Thickness LEARN FUNCTION is recommended. The
LEARN FUNCTION automatically sets the
All three sensor types can measure blanks as PRESET value (thickness) equal to the
thin as 0.1mm thick. Blanks thinner than this thickness (as measured by the sensor) for a
cannot be measured accurately. When single blank. Although the thickness as
monitoring thin sheets for double blank measured will be less than the actual
conditions, the resolution of the system must thickness, the measurements by the DBD will
also be considered. The DBD and sensor, as be consistent. This ensures accurate double
a system, is capable of measurements that blank detection.
are resolved to within +/- 0.1mm. Based on
this, the minimum blank thickness and Questions regarding the measurement of
therefore the minimum PRESET, that will high carbon or stainless steels with the DBD
insure detection of a double blank condition, should be referred to Syron's Application
is 0.6mm for all sensors. Engineering Department.

6-2
Chapter 7:
Sensor Mounting Considerations

This section discusses proper sensor application department for help in selecting
mounting techniques for the various sensors the best option for your application.
used with the DBD.

The DBD uses a pulsed magnetic technique. Sensor Mounts

Its intended application is for measuring the
thickness of ferrous materials. This A resilient mounting configuration in which
technique requires that the sensors make the sensor is suspended by a large spring as
contact with the material to be measured. shown in Figure 7-2. This isolates the mass
of the sensor from the mass of the support
The sensor must be mounted in such a way structure and allows the sensor to adjust itself
that its entire sensing face is able to sit flat on to the surface of the material it is measuring.
the surface of the material to be measured.
Any variable air gap or imperfect contact
between the sensor and the material 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. Figure 7-1
illustrates an example of incorrect sensor
seating.

SENSOR

Figure 7-2

Figure 7-1
Syron has developed a series of resilient
mounts based on this principle. These
At the same time, care must be taken to resilient mounts employ a flexible single-
cushion the impact of the sensor as it spring concept which not only allows the
contacts the material. The sensors are sensor to sit flat on the surface of the
solidly built, and are rather heavy. If one material, but also acts to absorb shock.
impacts the material with too much force, it
may dent or scratch the surface of the
material. If the sensor is rigidly mounted, the
mass of the actuating mechanism adds to the
mass of the sensor, making the impact that
much more severe. Bumpers are available
from Syron to protect sensitive surfaces.
Bumpers will reduce the maximum sheet
thickness for a sensor. Contact our

7-1
NOTE: Syron Engineering & As shown in Figure 7-3 if there is any motion
Manufacturing Corporation warrants the of the material relative to the sensor, the
proper function of the DBD system only sensor can be moved out of position causing
when original Syron sensor mounting improper thickness readings and, most likely,
fixtures are used. cause scratching of the surface of the
material.

Due to the type of measurements the sensor

performs, the sensor should only be used on
material which is stationary relative to the
sensor for the duration of the measurement.
During a measurement cycle, the sensor
creates a strong magnetic field which attracts
the material to the sensor. To get an
accurate thickness reading, the sensor must
remain in contact with that particular spot on
the material for the entire measuring cycle.

MATERIAL

Figure 7-3

7-2
Appendix A:
Dimensional Information

A-1
Housing Dimensions:

216mm[8.50”]

10mm[.41”]

165mm[6.50”]

25mm[1.00”]

83mm[3.25”]

NOTES:
• Dimensions are in millimeters with equivalent [inches] shown in brackets.
• Drawing not to scale.
• Specifications are subject to change without notice.

A-2
Mounting Dimensions:

227mm[8.94”]
181mm[7.12”]

8mm[.31”] x 13mm[.50”]
MOUNTING SLOT

102mm[4.00”] #10-32
PAN HEAD SCREW

14mm[.54”]

NOTES:
• Dimensions are in millimeters with equivalent [inches] shown in brackets.
• Drawing not to scale.
• Specifications are subject to change without notice.

A-3
Sensor Dimensions:

NOTES:
• Dimensions are in millimeters with equivalent [inches] shown in brackets.
• Drawing not to scale.
• Specifications are subject to change without notice.

A-4
Appendix B:
Wiring Information

B-1
Wiring Information:

Fault Relay

Double Blank (Part) Relay

Single Blank (Part) Relay

Part Present Relay

Inhibit

Safety Ground

Power Input
WHT/GRN
GRN
VLT
RED
GRY
PNK
BLU
BLU/RED
WHT
YEL
GRY/PNK
BRN/GRN
Sensor
BLK Cable
(SHIELD)
BRN

NOTES:
• Drawing not to scale.
• Specifications are subject to change without notice.

B-2
DOUBLE BLANK DETECTOR

THE MEASURING DEVICE FOR MATERIAL

THICKNESS GAUGING

Machinery Protection Technology