PRÜFTECHNIK EDDYSENSOR Operating Manual
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PRÜFTECHNIK EDDYSENSOR Operating Manual

PRÜFTECHNIK EDDYSENSOR Operating Manual

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EDDYSENSOR
Operating manual
Doc. no. LAB 5329
Release 26.8.97 Release 4

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Summary of Contents for PRÜFTECHNIK EDDYSENSOR

  • Page 1 EDDYSENSOR Operating manual Doc. no. LAB 5329 Release 26.8.97 Release 4...
  • Page 2 EDDYCHEK ® is a registered trademark of PRÜFTECHNIK PRÜFTECHNIK NDT GmbH AG. The information contained in this leaflet is subject to Fischerfleck 8 change without further notice due to the PRÜFTECHNIK D-85737 Ismaning, Germany policy of continuous product development. Telephone: +49 (0) 89/9 96 16-0 ©...

  • Page 3: Table Of Contents

    EDDYSENSOR Operating Manual Contents Page Safety instructions iv - vi System diagram Backplate connections of the EDDYSENSOR 1030 Front End Unit Front module Setting the gain LED monitoring function Filtering Filter setting F3 filter F1 and F2 filters Filter-to-speed relationship for filters F1 and F2...
  • Page 4 Fuses up to modification status d Fuses from modification status e onwards Changing a fuse LAB 1110 connection box Power unit Function Front module Fuses for mains and operating voltages Changing fuses Back module Example: WICU line with encoder 29-31 EDDYSENSOR Operating Manual...
  • Page 5 PCB of the back module Fuses up to modification status d Fuses from modification status e onwards Replacing the fuses Power unit Fuses PCB of the front module Replacing the fuses Appendix - Filter tables Technical data EDDYSENSOR Operating Manual...
  • Page 6 (For actual dimensions, see "Technical Data" at the back of the operating manual.) Technical data The technical data relevant to this equipment is listed at the back of the Operating Manual. EDDYSENSOR Operating Manual...

  • Page 7: Safety Instructions

    • Repair work must only be carried out by authorized specialists • Use only original spare parts and accessories • Only trained personnel may carry out service and maintenance • Any modification carried out without the agreement of the manufacturer invalidates the guarantee EDDYSENSOR Operating Manual...
  • Page 8 Exchanging the plug-in modules EDDYSENSOR Operating Manual...

  • Page 9: System Diagram

    Back module DM1050F DI1050BA The EDDYSENSOR is a simple eddycurrent detection The minimum configuration is made up of the Front device which senses the presence of a defect to End Unit in the left-hand position and the Power Unit in activate subsequent activities, e.g.

  • Page 10: Backplate Connections Of The Eddysensor

    Delay Unit The diagram shows the backplate of the EDDYSENSOR. The inputs and outputs are also shown. The output signal for the configuration without the Delay Unit is taken from the backplate of the Front End Unit whereas for the configuration with the Delay Unit, the delayed output signal is taken from the potential-free output on the backplate of the Delay Unit.

  • Page 11: 1030 Front End Unit

    The bar graph display shows the amplitude of the signal from the coil. The defect threshold value is fixed at 50% of the full bar graph display. Any signal EDDYSENSOR from above Back above this level (shown by red LEDs) is considered a defect signal and any signal below the level (shown by green LEDs) is not.

  • Page 12: Filtering

    Filtering There are three filters available for the EDDYSENSOR. The application dictates which filter is required. The F1 and F2 filters for this module consist of a variable low pass and high pass filter which combine to provide variable band pass filters. Because the coils and their sensing widths are known we can calculate the filter range in speed as this is more appropriate in practice than Hz.

  • Page 13: F1 And F2 Filters

    For optimum results the band pass should be as wide as possible but as narrow as necessary. To give a reasonable bandwidth we recommend: / 4: Switch setting HPH/HPL Line x 2: Switch setting LPH/LPL Line EDDYSENSOR Operating Manual...
  • Page 14 Graph of the F1 and F2 filter settings for slow applications (Speed range 0 - 300 m/min) EDDYSENSOR Operating Manual...

  • Page 15: Graph Of The F1 And F2 Filter Settings For Normal Applications

    Graph of the F1 and F2 filter settings for normal applications (Speed range 20 -1800 m/min) EDDYSENSOR Operating Manual...

  • Page 16: Graph Of The F1 And F2 Filter Settings For Fast Applications

    Graph of the F1 and F2 filter settings for fast applications (Speed range 150 - 8000 m/min) EDDYSENSOR Operating Manual...

  • Page 17: Back Module

    1030BA provides a coil connection and 1030BA outputs for the analogue defect signal and for the digital defect level. This EDDYSENSOR from above unit is supplied in a number of frequency versions: Back 5 - 10 - 20 - 50 - 100 - 250 kHz.

  • Page 18: Connection Of Plc Or Similar

    Digital I/O Defect + pole (60V 100mA), switching duration = min. 200 ms Defect – pole (60V 100mA) Example of use: alarm lamp Internal electronic Switching duration: switch min. 200 ms, max. 60V 100mA EDDYSENSOR Operating Manual...

  • Page 19: 1031 Front End Unit

    The bar graph display shows the peak amplitude of the signal from the Front Module coil. The defect threshold value is fixed at 50% of the full bar graph display. EDDYSENSOR from above Any signal above this level (shown by a bar of red LEDs) is considered a Back defect signal and any signal below the level (shown by a bar of green LEDs) is not.

  • Page 20: Functions Of The Gain Switch

    55 dBs using the rocker switch. Set the gain high enough so that the smallest detectable defect reaches approx. 60% on the bar graph display but low enough to prevent noise interfering with the test results. The gain is permanently stored after being set up. EDDYSENSOR Operating Manual...

  • Page 21: Filtering

    The high pass setting and the low pass setting to- gether form the required band pass filter. The settings required for a spe- cific line speed are given in the following table. The filter settings, like the gain, are permanently stored after being set up. EDDYSENSOR Operating Manual...
  • Page 22 • After several seconds if the switch has not been touched, the display returns to the original gain mode The filter settings, like the gain, are permanently stored after being set up. EDDYSENSOR Operating Manual...

  • Page 23: Filter Settings For F3

    Look in the filter table for the speed under the required probe type and read off the setting required for the filter. The filter settings, like the gain, are permanently stored in the module after Please note being set up. EDDYSENSOR Operating Manual...

  • Page 24: Filter Settings For Fi 1031 F1 And F2

    12.00 121.00 20.5 16.00 164.00 27.4 21.00 207.00 28.00 276.00 37.00 372.00 63.4 1062 49.00 492.00 1406 65.00 648.00 1110 1851 87.00 873.00 1496 2494 116.00 1.158.00 1985 3310 154.00 1.538.00 2636 4394 206.00 2.056.00 3524 5874 EDDYSENSOR Operating Manual...

  • Page 25: Connection Of Display Device

    The back module of this unit FI 1031BAfff (where fff is the test frequency) provides a coil connection and outputs for the analogue defect signal and EDDYSENSOR from above for the digital defect level. This unit is supplied in a number of frequency...

  • Page 26: Connection Of Plc Or Similar

    Digital I/O Pin 5 Defect + pole (60V 100mA), switching duration = min. 200 ms Defect – pole (60V 100mA) Application example: alarm lamp Internal electronic Switching duration switch = min. 200 ms Max. 60V 100mA EDDYSENSOR Operating Manual...

  • Page 27: Delay Unit

    It provides two delayed outputs of the defect signal to use for processes such as colour marking or sawing and an undelayed output for immediate switching or warning purposes. Front Module DM 1.050F EDDYSENSOR from above LEDs show: Back Encoder Encoder pulses where an encoder is used...

  • Page 28: Switch Settings

    WIDTH switches on the right of the row together with the scaling factor (1s/0.1s) given by position 1 of the Channel switch (see below). Switch setting Duration Scaling factor (WIDTH switch) (Channel switch Pos. 1) 0.1s 100 - 900ms 1 - 9s EDDYSENSOR Operating Manual...

  • Page 29: Prescaler

    WO (wired OR) on leaving the factory. OUT1 WO is always activated when a defect signal arrives. For EDDYSENSOR, it does not need OUTPUT switches to be changed. The ON position is indicated by the position of the numbers.

  • Page 30: Back Module

    Back Module On the back module of the Delay Unit there is an Harting DI 1.050BA socket for input from the Encoder. The encoder pulses EDDYSENSOR from above are used subsequently when locating any defects. The Back Encoder unit is designed to work not only with the standard PRÜFTECHNIK encoder but also with encoders from...

  • Page 31: Encoder Socket Pin Assignment

    +5 Volt with switch +5V ON (ext. voltage with switch +5V OFF), I = 200 mA Only for PRÜFTECHNIK standard encoder Clock ––– ––– ––– ––– Encoder socket GND with switch GND ON Ext. GND with switch GND OFF EDDYSENSOR Operating Manual...

  • Page 32: Output Sockets

    = 200 mA = 200 mA * The current modification status of the PCB is indicated by an identifying letter on the connector block of the PCB OUTx (+) Switching duration depends on settings of DM1050F OUTx (–) EDDYSENSOR Operating Manual...

  • Page 33: Fuses Up To Modification Status D

    Pull the module carefully out of the housing. Remove the blown fuse(s). Insert the new fuse(s). Slide the back module into its slot in the housing and seat it firmly. Tighten up the four retaining screws again. EDDYSENSOR Operating Manual...

  • Page 34: Lab 1110 Connection Box

    LAB 1110 The connection box enables standard peripherals (paint marker, horn etc.) connection box to be connected directly to the EDDYSENSOR without any rewiring. Cable from 1050BA Power cable to mains OUT1 OUT2 OUT3 OUT4 The connection box has two cables to it. These are: •...

  • Page 35: Power Unit

    Power Unit Front module Back module EDDYSENSOR from above Back PI1040BA PM1040F Front The Power Unit generates the supply voltages. Function The Power Unit is switched on by the ON/OFF switch on the front panel. The Front Module supply voltages of +15, – 15 and +5 volts are generated by a transformer on the input mains supply of 115V/230V.

  • Page 36: Changing Fuses

    LAB 1004 housing. On the panel of the back module next to the power socket, there is a switch to select between 115/230 V mains supply. Power socket Mains supply switch to select Disconnect Vor Öffnen before Netzstecker 115 V or 230 V opening! ziehen! EDDYSENSOR Operating Manual...

  • Page 37: Example: Wicu Line With Encoder

    From the table or the graph for the low pass filter using an encircling coil, the setting of the switches LP is 11. Set the filter switches to the correct settings as explained in the module description. EDDYSENSOR Operating Manual...
  • Page 38 PCB up to mod. status d Setting for non-standard Setting for standard encoders from other PRÜFTECHNIK encoder manufacturers for PCB from mod. status e Setting for non-standard Setting for standard encoders from other PRÜFTECHNIK encoder manufacturers EDDYSENSOR Operating Manual...
  • Page 39 OUT1 WIDTH switch. The OUT1 delay for the flying saw at a distance of 22.5 m =a setting of 2250. The WIDTH for OUT1 is set to 0 for the default signal duration of 1 s. EDDYSENSOR Operating Manual...

  • Page 40: Pin Allocation Of The I/O Sockets

    +5 Volt with switch +5V ON (ext. voltage with switch +5V OFF), I = 200 mA Only for PRÜFTECHNIK standard encoder Clock ––– ––– ––– ––– GND with switch GND ON Ext. GND with switch GND OFF Encoder socket EDDYSENSOR Operating Manual...

  • Page 41: Potential-Free Output Socket

    DC - 48 V max. OUT4 – (not used) 1.25 A max. + 15 Volt = 200 mA = 200 mA + 5 Volt = 200 mA = 200 mA OUTx (+) Switching duration depends on settings of DM1050F OUTx (–) EDDYSENSOR Operating Manual...

  • Page 42: Examples Of Connections Using Digital I/O Socket Output

    Lamp EDDYSENSOR Alarm unit via a time-lag relay using the EDDYSENSOR internal current supply The internal current supply of the EDDYSENSOR (pin 6, 24V, I = 100mA) can be used to switch a relay if no external current supply is available.

  • Page 43: Locating And Changing Fuses

    Pull the module carefully out of the housing. Remove the blown fuse(s). Insert the new fuse(s). Slide the back module into its slot in the housing and seat it firmly. Tighten up the four retaining screws again. EDDYSENSOR Operating Manual...

  • Page 44: Power Unit

    (F1 or F5). PCB of the front module Fuse F4 for Fuse F3 for Fuse F2 for –15V supply +15V supply 5V supply EDDYSENSOR from above Back PM1040F Front Fuse F5 for 115/ Fuse F1 for 115/ 230V supply 230V supply...

  • Page 45: Appendix - Filter Tables

    To achieve a reasonable bandwidth we recommend: / 4: Switch setting HPH/HPL Line x 2: Switch setting LPH/LPL Line Select the value nearest to the speed calculated (for both the low pass and high pass filters). EDDYSENSOR Operating Manual...
  • Page 46 EDDYSENSOR Operating Manual...

  • Page 47: Technical Data

    •Resolution: 10,000µm/pulse Display •Operating temperature range: 0 – 70°C (32 – 158°F) Two-color bar graph display Marker Indicator LEDs •Air pressure marker •Overload •Heat resistant ink and paint •Defective coil or connection •Power supply: 24V •Defect occurred EDDYSENSOR Operating Manual...
  • Page 48 EDDYSENSOR filter settings Front end unit 1030 Switch Low pass filter High pass filter Defect Encircling Segment Defect Encircling Segment E coil E coil frequency coil coil frequency coil coil 1008 1037 1066 1094 1123 1152 1181 1210 1238 1267...
  • Page 49 2419 1700 1224 2448 1720 1238 2477 1740 1253 2506 1760 1267 2534 1780 1281 2563 1800 1296 2592 1820 1310 2621 1840 1325 2650 1860 1339 2678 1880 1353 2707 1900 1368 2736 EDDYSENSOR Operating Manual Filter settings 2...
  • Page 50 1958 3917 2740 1184 1973 3946 2760 1192 1987 3975 2780 1201 2001 4003 2800 1210 2016 4032 2820 1218 2030 4061 2840 1227 2045 4090 2860 1236 2059 4119 2880 1244 2073 4147 EDDYSENSOR Operating Manual Filter settings 3...
  • Page 51 2664 5328 3720 1607 2678 5357 3740 1616 2693 5386 3760 1624 2707 5415 3780 1633 2721 5443 3800 1642 2736 5472 3820 1650 2750 5501 3840 1659 2765 5530 3860 1668 2779 5559 EDDYSENSOR Operating Manual Filter settings 4...
  • Page 52 3369 6739 4700 2031 3384 6768 4720 2039 3398 6797 4740 2048 3412 6826 4760 2056 3427 6855 4780 2065 3441 6883 4800 2074 3456 6912 4820 2082 3470 6941 4840 2091 3484 6970 EDDYSENSOR Operating Manual Filter settings 5...
  • Page 53 3571 7143 4980 2152 3585 7171 5000 2160 3600 7200 5020 2169 3614 7229 5040 2177 3628 7258 5060 2186 3643 7287 5080 2195 3657 7315 5100 2203 3672 7344 5120 2212 3686 7373 EDDYSENSOR Operating Manual Filter settings 6...

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