Model DS1522

The Model DS1522 Double Metal Sheet and Blank Detector is the ultimate detector in metal thickness versatility. The primary function is to detect double sheets or blanks prior to metal forming or stamping operations.

Accuracy: In many cases it is an alternative to more expensive metal thickness monitors. Detection of variations in thickness as small as 5% are possible. For example, measurement of metal that is .5 mm has a detection accuracy of +/-.025 mm (.020” to +/-.001”).

Output: Dry contact outputs are available for Over, Under, Normal thickness and Nothing present. Up to sixty-four (64) separate metal gauges are stored and recalled later through an external binary code from a PLC or through the front panel. Ferrous and nonferrous metals over a range of .05 mm to 8 mm (.002” to .300”) may be measured with any of Prime’s dual probes, except Models AX, P1C & P1CS.

When a machine operator changes the configuration of the machine through a PLC, the DS1522 is automatically changed by the PLC without the involvement of the operator.

Calibration is simple and reliable. Select one memory position out of sixty-four. Place a metal sheet or blank between the probe assembly and push the calibrate button. In the single calibrate mode that is all that is required. The DS1522 estimates the second thickness and sets the Over and Under thresholds.

To monitor thickness values there are not double, a second teach method allows two thickness examples to set a range between acceptable and reject. Once the metal thickness examples are entered, the detector automatically sets the reject threshold value at 50% between the two sheet examples. Repeat both steps for up to sixty-four separate gauge sizes.

To tighten tolerances more, the 50% reject threshold setting is adjustable. This is accomplished by manually holding the calibrate button in for 3 seconds. The display changes and prompts either OT (over tolerance) or UT (under tolerance). Releasing and pushing the button again advances the tolerance value over a range of 1 to 99%.

As a double metal detector the Model DS1522 can discriminate single, double, and no-metal conditions. As a coil thickness or weld splice monitor it can detect under, over (weld), and nothing present conditions.

An optional Tracking Nominal feature automatically adjusts for slow changes in nominal thickness.

No need to worry about loosing values. Nonvolatile memory keeps all sixty-four gauge and threshold settings if power is lost.

Review Wiring Diagram

See Operating Instructions for installation review

Prices

Specifications

Power input: 100 to 240 VAC, 50/60 Hz 300 mA operating load

Outputs: 2 SPDT contact relays (Over, Under)

Max load: 10 Amps @ 240 V AC 8 Amps @ 24 V DC ½ HP @ 240 V AC Output fail safe: Defaults to reject w/power off

Output response: < 16 milliseconds plus "ry" setting

Probe recognition: Determines probe type, probe separation, with nothing present signal level, when "Calibrate Gap" button is pushed

Memory storage Stores up to sixty-four (64) separate gauge applications

Memory recall Recall through front panel Display/Select pushbutton or binary code through external terminal strip 64 separate applications

Thickness range: .05-8 mm (.002-.240”) Ferrous (steel, magnet stainless). 11 mm (.450”)Nonferrous (thicker for aluminum, copper, magnesium, non magnetic stainless steel).

Probe separation: 12 mm to 75 mm (.5 to 3”) or more. Max. varies w/(metal, thickness & probe, separation).

Maximum range is realized with Model P1000B transmitter & receiver probes.

Tracking Nominal (Floating Reference)Original nominal calibration is allowed to adjust with slow changes in metal thickness. Tracking up to 50% over original measurement. Time constant of 500 millisecond to change .5 of actual measurement. Primarily used for monitoring secondary coil stock for welds.

Calibration methods: Auto calibration after absence of metal for a time interval between 6 sec. to 24 min. Push-button switch used to change time interval or manually initiate calibration. Two sample calibration. Manually place two samples between probes, push Cal. button.

Reject threshold: Defaults at 25% over single sample calibration; 50% between two sample calibration. Variable through front panel in 1 % increments.

LED indicators: Green for Nominal, Amber for Over, Under & Nothing detected.

Sensor operation: Inductive or Eddy Current in metal impedes signal from transmitter to receiver. Impedance changes as metal thickness changes.

Display Indication: 4 digit LED, alphanumeric, .5 inch high. Displays setup, calibration mode, operating probe signal strength, fault codes.