Contec Stud Sensor CS2000 User Manual

INTELLIGENT LABEL SENSORS

OPERATIONS MANUAL

CS2000 & CS2000-QD

CONTROL TECHNOLOGIES

2617 Fremontia Drive

San Bernardino, CA 92404

Phone: 877-880-5389

Fax: 877-880-5537

www.con-tech.com

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General Information

Features:

•

10 to 30 VDC input - reverse polarity protected

Fast RISC microprocessor controlled

Easy one touch setup - label sensitivity easily adjusted, to the optimal setting, by

the push of a button

•

Missing label compensation - outputs a stop pulse even when a label is missing

Level shift or leading edge pulse output selectable

Light or dark operation selectable

Low label contrast setting available

Push-button may be momentarily depressed to output a stop pulse - very useful

during machine setup

•

All settings saved in nonvolatile memory (EEPROM) - settings are not affected

by power loss

NPN or PNP output selectable - 100mA, open collector, reverse polarity and

short circuit protected

•

Precision machined and double anodized aluminum housing

8 mounting holes - allows for many different mounting options

Large throat - 3" deep x 0.093 wide

Optional 6" quick disconnect M12 - 4 pin male cable/connector (Turck P/N RS4.4T-2)

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General Information

CS2000 Diagram:

Red LED:

Indicates output state

Yellow LED:

Indicates label

backing (web)

Green LED:

Indicates label

+ label backing

Push-button

WEB OUT LABEL

EASY SETUP

1.Position

web

under sensing

area and hold

button down until

yellow

LED

comes on.

2.Release button

and yellow LED

will flash.

3.Move label under

sensing area and

green LED will

come on.

4.Setup complete.

Throat

#8-32 Mounting Holes

CS2000

Optional 6" Quick Disconnect

4 Pin Male Cable/Connector

Sensing

Area

#8-32 Mounting Holes (x6)

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General Information

CS2000 Quick Start:

Connect red wire to supply voltage

Connect black wire to supply common

For NPN Output - connect orange wire to black wire

For PNP Output - connect orange wire to red wire

Connect white wire to your controller - refer to page 6 for wiring diagrams

Turn on power

Peel off a label and position the label backing (web) under the sensing area

Depress the push-button until the yellow LED comes on (1 sec.), then release

The yellow LED will begin flashing

Move a label under the sensing area and the green LED will come on

10. The label sensitivity is now adjusted and the sensor should function correctly

11. The yellow LED indicates when label backing (web) is detected

12. The green LED indicates when label over label backing is detected

13. The red LED indicates when the output is active - NPN sinking or PNP sourcing

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General Information

CS2000-QD Quick Start:

Plug the CS2000-QD's male connector into a suitable 4 pin female connector

Connect brown wire to supply voltage

Connect blue wire to supply common

For NPN Output - connect black wire to blue wire

For PNP Output - connect black wire to brown wire

Connect white wire to your controller - refer to page 7 for wiring diagrams

Turn on power

Peel off a label and position the label backing (web) under the sensing area

Depress the push-button until the yellow LED comes on (1 sec.), then release

The yellow LED will begin flashing

10. Move a label under the sensing area and the green LED will come on

11. The label sensitivity is now adjusted and the sensor should function correctly

12. The yellow LED indicates when label backing (web) is detected

13. The green LED indicates when label over label backing is detected

14. The red LED indicates when the output is active - NPN sinking or PNP sourcing

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Installation

Mounting:

The CS2000 comes with 8 mounting holes allowing for many different mounting options. The

holes are tapped for #8-32 screws and are 0.31" deep. We suggest using #8-32 x 3/8"

stainless steel screws. Some different options are shown below.

FORK

* To avoid electro-static discharge and sensor malfunction, the CS2000 should be mounted to

a grounded metal surface. If this is not possible, a grounding wire should be connected from

one of the mounting screws to a suitable ground.

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Installation

CS2000 Wiring:

The CS2000 comes with an 8' - 4 conductor cable. Refer below for wire designations.

RED = 10-30 VDC

BLK = Common

WHT = Output

ORN = NPN / PNP Output Selector

Interfacing to Load - NPN Output:

Interfacing to Load - PNP Output:

RED

CS2000

10-30V

CS2000

10-30V

BLK

WHT

ORN

WHT

LOAD

Interfacing to 5V Logic - NPN Output:

Sourcing Other than Supply Voltage - PNP Output:

RED

Supply

10-30V

BLK

ORN

WHT

CS2000

Voltage

+5V

1/4W

Output

Source

Voltage

WHT

ORN

10-30V

LOAD

5V Logic

*5V Com. and 10-30V Com.

must be connected together

*Output Source Com. and Supply

Com. must be connected together

Interfacing to Optoisolator - NPN Output:

Interfacing to Optoisolator - PNP Output:

RED

10-30V

BLK

CS2000

ORN

Optoisolator

WHT

ORN

WHT

12V = 1K 1/4W

24V = 2K 1/4W

12V = 1K 1/4W

24V = 2K 1/4W

*Resistor values are to source approx.

10mA to the optoisolator

*Resistor values are to source approx.

10mA to the optoisolator

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Installation

CS2000-QD Wiring:

The CS2000-QD comes with a 6" quick disconnect M12 - 4 pin male cable/connector (Turck

P/N RS4.4T-2). Refer below for wire designations.

Pin 1. BRN = 10-30 VDC

Pin 2. WHT = Output

Pin 3. BLU = Common

Pin 4. BLK = NPN / PNP Output Selector

Interfacing to Load - NPN Output:

Interfacing to Load - PNP Output:

BRN

CS2000-QD

10-30V

CS2000-QD

10-30V

BLU

WHT

BLK

LOAD

WHT

LOAD

Interfacing to 5V Logic - NPN Output:

Sourcing Other than Supply Voltage - PNP Output:

BRN

Supply

10-30V

BLU

BLK

WHT

CS2000-QD

Voltage

+5V

1/4W

Output

Source

Voltage

WHT

BLK

10-30V

LOAD

5V Logic

*5V Com. and 10-30V Com.

must be connected together

*Output Source Com. and Supply

Com. must be connected together

Interfacing to Optoisolator - NPN Output:

Interfacing to Optoisolator - PNP Output:

BRN

10-30V

BLU

BLK

CS2000-QD

Optoisolator

WHT

BLK

WHT

12V = 1K 1/4W

24V = 2K 1/4W

12V = 1K 1/4W

24V = 2K 1/4W

*Resistor values are to source approx.

10mA to the optoisolator

*Resistor values are to source approx.

10mA to the optoisolator

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Operation

Label Placement:

For best results, position straight edge of label under the sensing area. Try to avoid sensing

on rounded corners or other curved areas. Refer to diagram below.

ACME LABELS

Sensing

Area

ACME LABELS

Web (label backing)

ACME LABELS

Label

ACME LABELS

Push-button Functions:

Push-button is depressed for...

LED's

Function

Less than 1 second

YEL/GRN - off

Outputs a stop pulse

1 to less than 5 seconds

5 to less than 10 seconds

30+ seconds

YEL - on

Adjust Label Sensitivity

(refer to page 10)

GRN - on

Set Missing Label Compensation

(refer to page 11)

YEL/GRN - toggle

Enter Program Mode

(refer to page 12)

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Operation

LED Functions:

Yellow - comes on when label backing (web) is under the sensing area

Red - comes on when output is active - NPN sinking or PNP sourcing

Green - comes on when label over label backing is under the sensing area

Operation Features:

The CS2000 has 3 different operation features that can be changed to accommodate

individual needs. They are Output Mode, Light/Dark Operation, and Contrast Setting.

Operation Features - Output Mode:

The CS2000 has 2 different output modes - Level Shift Output and Pulse Output. Level

Shift Output is either on for the length of the web, or on for the length of the label, depending

on the Light/Dark Operation setting. Pulse Output either comes on for 2 m.s. at the leading

edge of a label, or goes off for 2 m.s. at the leading edge of a label, depending on the

Light/Dark Operation setting. Refer to Program Mode (page 12) for more information.

Operation Features - Light/Dark Operation:

The CS2000 allows you the option of having the sensor's output active on the web

(Light Operate), or having the sensor's output active on the label (Dark Operate). Light Operate

is either on for the length of the web, or comes on for 2 m.s. at the leading edge of a label,

depending on the Output Mode setting. Dark Operate is either on for the length of the label, or

goes off for 2 m.s. at the leading edge of a label, depending on the Output Mode setting.

Refer to Program Mode (page 12) for more information.

Operation Features - Contrast Setting:

The CS2000 comes with a Normal Contrast Setting and a Low Contrast Setting.

Normal Contrast Setting should be fine for 99% of labels. But with labels that offer very little

contrast between the web and the label, the Low Contrast Setting can be selected very easily.

Refer to Program Mode (page 12) for more information. Adjustments to the label sensitivity

should be made more frequently when the Low Contrast Setting is selected.

*Factory Settings:

Output Mode...............................................................Factory set to Level Shift

Light/Dark Operation....................................................Factory set to Light

Contrast Setting...........................................................Factory set to Normal

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Adjusting Label Sensitivity

Overview:

The CS2000 will automatically adjust its label sensitivity, to the optimal setting, by

simply depressing a push-button. This adjustment process is referred to as "Easy Setup." It is

recommended that the operator adjust the label sensitivity for each new roll of labels due to

differences in label rolls.

Easy Setup:

To adjust label sensitivity for each new roll of labels follow steps 1-4.

1. Peel off a label and position the web (label backing) under the sensing area.

2. Depress the push-button until the yellow LED comes on (1 sec.), then release.

3. The yellow LED will begin flashing.

4. Move a label under the sensing area and the green LED will come on.

The sensor is now adjusted and should function correctly.

*Note: If in the Adjusting Label Sensitivity mode by mistake, the push-button may be

depressed to exit with no changes made.

Possible Problems:

Symptom

Problem

Solution

Red LED flashes after the

push-button is released.

The sensor cannot adjust

to the label backing.

Probable cause is a build

up of paper dust or some

other obstruction is under

the sensing area.

Blow out any paper dust

present and remove any

obstructions, labels, or

label residue from sensing

area (refer to page 15).

Yellow LED continues flashing

even after a label is placed

under the sensing area.

There is not enough

contrast between the label

and the label backing.

Try the Low Contrast

Setting. See Program

Mode (page 12) for more

information.

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Missing Label Compensation

Overview:

The CS2000 has the capability to detect a single missing label and output a stop pulse as

though the label were present. In order for Missing Label Compensation to function properly the

operator must first: a) have Pulse Output selected - see Program Mode (page 12) for more

information. b) adjust the label sensitivity - see Easy Setup (page 10) for more information. c)

have the labeling machine set to desired speed.

Enabling Missing Label Compensation:

Make sure a label is under the sensing area.

Depress the push-button until the green LED begins flashing at a slow rate

(5 sec.), then release. If the green LED flashes at a fast rate it indicates that the

label was not positioned correctly and you need to start over.

Jog 1 label.

Missing Label Compensation is now enabled and should function correctly.

Disabling Missing Label Compensation:

Depress the push-button until the green LED begins flashing (5 sec.), then release.

Depress the push-button once again to disable.

*You can also disable Missing Label Compensation by selecting Level Shift Output. Refer to

Program Mode (page 12) for more information.

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Program Mode

Entering Program Mode:

Program Mode is used to change any or all of the Operation Features. To enter Program

Mode depress the push-button until the yellow and green LED's begin toggling (30 sec.), then

release. The LED's will then output the current set-up configuration (and every 3 sec.

thereafter). For example: an output of yellow, yellow, yellow tells you that the current

configuration is Level Shift, Light Operate, and Normal Contrast Setting.

Table of Features:

OUTPUT MODE

Yellow LED

*A. Level Shift - (default factory setting)

B Pulse

Green LED

LIGHT/DARK OPERATION

*A. Output on Web - Light - (default factory setting)

Yellow LED

Level Shift Output

Pulse Output

WEB

LABEL

WEB

OFF

2 m.s.

Green LED

B. Output on Label - Dark

Level Shift Output

Pulse Output

WEB

LABEL

WEB

2 m.s.

OFF

CONTRAST SETTING

*A. Normal Contrast Setting - (default factory setting)

B. Low Contrast Setting

Yellow LED

Green LED

Changing a Feature:

To change a feature, depress the push-button the corresponding number of times. This

will change the current feature from A to B, or from B to A. For example: If you wanted to

change the output from Level Shift to Pulse, you would depress the push-button 1 time - the

LED's would then output green, yellow, yellow. Repeat this step if you want to change more than

one feature.

Exiting Program Mode:

To exit Program Mode depress the push-button until the yellow and green LED's begin

toggling (2 sec.), then release. This puts you back in the standard operating mode.

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Specifications

General:

Power Supply..................................................... 10-30 VDC, reverse polarity protected

Power Consumption............................................ 50mA max.

Output.............................................................. NPN / PNP open collector

Output Current................................................... 100mA max., reverse polarity & short

circuit protected

Response Time.................................................. 10 microseconds

Output Voltage Drop........................................... 0.5V max. (NPN) @ 10mA

1.5V max. (NPN) @ 100mA

0.5V max. (PNP) @ 10mA

1.5V max. (PNP) @ 100mA

Emission........................................................... IR LED (880 nm)

Indicators.......................................................... Yellow LED - Indicates label backing only

Red LED - Indicates output state and errors

Green LED - Indicates label + label backing

CS2000 Connections.......................................... 8' cable - 4 conductors

CS2000-QD Connections..................................... 6" Quick Disconnect M12 4 Pin Male

Cable/Connector (Turck P/N RS4.4T-2)

Slot Width......................................................... 0.093" (2.4mm)

Slot Depth......................................................... 3.00" (76.2mm)

Min. Label Gap (matrix) Detection......................... 0.03" (.76mm)

Housing Material................................................ Double Hard Anodized Aluminum

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Specifications

Dimensions:

0.44

11.2

0.625

15.9

0.09

2.4

0.50

12.7

1.00

25.4

0.53

13.5

0.38

9.5

0.22

5.6

0.625

15.9

0.75

19.1

0.625

15.9

WEB OUT LABEL

EASY SETUP

1.Position

web

under sensing

area and hold

button down until

3.00

76.2

yellow

comes on.

2.Release button

and yellow LED

will flash.

LED

3.50

88.9

2.00

50.8

3.125

79.4

3.Move label under

sensing area and

green LED will

come on.

4.Setup complete.

CS2000

0.59

1.00

25.4

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Cleaning Instructions

Cleaning Instructions:

Begin by removing the sensor lid's 4 screws with a 1/16" L wrench.

Gently lift the sensor's circuit board out by grasping the switch and pulling upward. Do not

remove the insulation tape.

Clean the lens of the sensor's photo eye with a clean soft cloth moistened with 99%

isopropyl alcohol (available from most electronics supply & tool distributors - e.g. Techni-

Tool, Contact East, Jensen Tools, Future Active, etc.)

Lightly scrape off sticky label residue using an Xacto knife with a #17, #18, or #19 chisel

blade. The CS2000 has double hard anodizing that is not easily penetrated, but

nonetheless, care should be taken when using the Xacto knife.

Fold the cloth over a couple of times to make it thicker. Saturate a 2" x 2" area on the

edge of the cloth with 99% isopropyl alcohol.

Insert the wet area of the cloth into the throat of the sensor. Pull the cloth back and forth

(like shining shoes) to loosen up the sticky residue.

Repeat steps 4 through 6 as necessary until all traces of residue have been removed.

Insert a cotton swab dipped in 99% isopropyl alcohol into the hole on the top half of the

sensor's case intended for the photo eye.

Rub the lens of the photo emitter (located on bottom half of sensor case) with the cotton

swab to remove any residue present.

10. Verify that the insulation tape is still in place and re-install the sensor's circuit board.

11. Re-insert the sensor's cable into the strain relief slot located in the top/rear of the case.

12. Re-install the sensor's lid making sure the cable is pinched tight and cannot be pulled out.

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Warranty Terms & Conditions

Warranty:

The CS2000 Label Sensor is warranteed for a period of two (2) years from the time of

purchase. Control Technologies guarantees the CS2000 to be free from defects in materials

or workmanship, and that, if used correctly will perform within specifications. The warranty

covers normal wear and tear, but does not cover physical abuse, physical damage, improper

installation, or exposure to voltages greater than 35V. The warranty also does not cover

standard maintenance such as removal of paper dust, label residue build up, regular cleaning,

etc. If a CS2000 is found to be defective while still under warranty, Control Technologies will

either repair or replace the defective label sensor at our discretion. For warranty repair

service, the OEM should send defective label sensor to Control Technologies with a brief

description of the problem and sample labels if available.

Repairs:

CS2000 Label Sensors out of warranty will be repaired (if possible) at a flat rate. As of

01/01/2003 this rate is $50. For non-warranty repair service, the OEM should send

defective or damaged label sensor to Control Technologies with a brief description of the

problem and sample labels if available.

After Repair Warranty:

Upon completion of repair to CS2000 Label Sensor out of warranty, a new warranty

for a period of six (6) months will be issued.

Liability:

Control Technologies assumes no liability, in any event, for any consequential damages;

for anticipated or lost profits, incidental damages or loss of time or other losses incurred by

purchase or any third party in connection with the CS2000 Label Sensor covered by this

warranty or otherwise.

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