Model WHD Weld Hole Detector Operator s Manual Rev 1.1
Contents 1. Introduction... 2 2. Description... 2 2.1 Model Nomenclature... 2 2.2 Operating Principle... 2 2.3 Specifications... 3 3. Location and Mounting... 4 3.1 Sensor Location... 4 3.2 Sensor Mounting... 4 4. Utility Connections... 5 4.1 Electrical Connections... Error! Bookmark not defined. 5. Operation... 6 5.1 Controls... Error! Bookmark not defined. 5.2 Debugging... Error! Bookmark not defined. 6. Maintenance... 6 6.1 Regular Maintenance... 7 6.2 Returns of the WHD... 7 P a g e 1
1. Introduction The Logika Technologies Weld Hold Detector, Model WHD, is primarily used in the metallurgical industry to detect weld holes in plate production lines. These holes are purposely made at weld seams so these seams may be later detected and cut out of the rolled product. The WHD consists of two parts: an emitter and a receiver. Typically, the Emitter is mounted above the sheet line and the Receiver directly below it so that the sheet blocks out the majority of ambient light. 2. Description 2.1 Model Nomenclature 2.2 Operating Principle The Logika Weld Hole Detector is comprised of an emitter and a receiver mounted above and below a steel sheet line. The emitter produces modulated infrared light that is collimated by a series of lenses. Normally, the steel plate blocks all of the light so that nothing reaches the receiver. Wherever a seam is welded in the steel plate, a hole is also punched to mark the seam. When a marked seam reaches the detect zone, the receiver will see the light through this hole and set an output. P a g e 2
2.3 Specifications Field of View: The length of the optical array is the same as the area scanned for weld holes. For single weld hole detection: 304mm(12 ) or 408 mm (16 ) Double hole detection 527mm (21 ) Max Sheet Speed: 900 m/min (2950 feet/min) Response: 1ms Working Distance: Weld hole 10mm (0.4 inches): Max working distance 1.2m (48 inches) Weld Hole 20 mm (0.8 inches): Max working distance 3m (118 inches) LED Indicator: Emitter : Green = power on, Red=emitter alarm Receiver: Red = detect, Yellow=sync alarm(on Alarm) Output: Relay contact (1NO,1NC) Contacts AC250V 5A; DC 30V 5A PNP output: maximum current 100mA with overload protection Output Delay: Output Signal Reset Delay, range from 0-4 sec Power Input: 24VDC±10%, 110VAC ±10%, 220ACV ±10% @ 20 VA Ambient: Temperature limits for electronics; -20 o C to 70 o C (-4 o F to 158 o F) Size See attached drawings Weight: 10 kg total (22 lbs) P a g e 3
3. Location and Mounting 3.1 Sensor Location The Logika WHD should not be installed above a significant heat source. Also avoid direct exposure to water vapor or excessive dust or smoke. The user may wish to improve the installation with heat shields or fans to dissipate the water vapor or smoke. Emitter and Receiver should be mounted as close as possible for receiver to get strongest infrared input signal. Maximum ambient temperature at the WHD is 70 o C (158 o F) 3.2 Sensor Mounting Installation- WHD comes with adjustable mounting brackets to align the emitter and receiver. Typically, the Emitter is mounted above the detect target with the lens facing down, the receiver is mounted underneath the target with the lens facing up, two lenses should be aligned properly by adjust the mounting brackets. Aiming- The emitter/receiver pair should be mounted so they are centered squarely across the product as it moves down the line. P a g e 4
4. Utility Connections Power Connections- Power Input (please specify power input at time of order). Number Color Function 1 Yellow +24VDC 2 Green 0VDC 3 Purple PNP Hi=Detect 4 Gray Relay NC. 5 White Relay Common 6 Pink Relay NO. Figure 4.1: WHD-S-24-P Cable Terminal Wiring Description Electrical Overview 1) Single Hole Detection Systems: All electrical connections to the WHD system are made via a 2m (7 ) 12-pin connector (with ground) on the Emitter. There is a second connection directly between the Emitter and Receiver via a 4 conductor, 3m (10 ) cable. Other cable lengths are available from Logika Technologies upon request. 2) Double Hole Detection Systems: All electrical connections to the WHD system are made via a 2m (7 ) 12-pin connector (with ground) on the Receiver. The Emitter is supplied with power only (110VAC or 220VAC) on a standard 2m (7 ) cable. Other cable lengths are available from Logika Technologies upon request. Cable Specification Outer steel braid for mechanical protection. Overall diameter of 9 mm. (0.35 ) Minimum bending radius of 30 mm. (1.18 ) Each conductor is color-coded and numerically tagged. Conductors are terminated with ferrules P a g e 5
Junction Box Wiring- Please see the Cable Terminal Wiring Description Figure 4.1 below for the sensor wiring terminal description. The supplied cable should be connected directly to the terminals of a junction box. All cables must be shielded all the way to the junction box with the shield connected to ground to eliminate electrical noise, which may trigger false detection. Any unused output wires must have insulation protection or be connected to a free terminal of junction box. 5. Operation 5.1 Single Hole System There are adjustment potentiometers on both Emitter and Receiver units. Receiver: Turning Time pot clockwise increases Detect signal on time(0-3s) Single Hole Debugging System does not detect weld holes: 1) Determine that the red Detect LED illuminates when no steel is present. If not, check power connections, Emitter/Receiver cable connections, Emitter/Receiver alignment. 2) If the red LED does illuminate but no signal is received by the line controller (PLC), check connections to the output lines. System Detect output stays on: Check alignment of WHD system to steel sheet. Ensure that the Emitter/Receiver pair is not past either edge of the sheet. 5.2 Double Hole System 6. Maintenance P a g e 6
6.1 Regular Maintenance Regular attention to the following will ensure steady operation of the sensor: Lens Cleaning- Routinely check the WHD lens glass for dust or oil residue. When necessary, clean the glass with alcohol and lens paper or soft cloth. 6.2 Returns of the WHD Contact LOGIKA at 1-888-856-4452 (1-888-8LOGIKA ) with the Serial Number of your sensor before you return our product. If we are unable to solve the problem by phone or email, LOGIKA will then provide you with a return authorization number. Do not return the WHD without an authorization number. If the product is out of warranty, we will provide a repair estimate and then complete the repairs after your approval. P a g e 7
7. Enclosure Dimensions 7.1 Single Hole WHD Emitter Steel plate Glass Receiver P a g e 8
7.2 Double Hole WHD Steel plate P a g e 9