15036_LaunderLine User's Manual
15036_LaunderLine User's Manual
User’s Manual
Selcom LaunderLine User’s manual
TABLE OF CONTENTS
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The Selcom XLine sensor family from LMI Technologies is a series of laser sensors
dedicated to measuring levels of molten aluminium in all common applications required
throughout the foundry process.
All XLine sensors are built around the same technology platform, incorporating the latest
imaging techniques and proprietary algorithms to eliminate disturbing influence from
smoke, steam and high reflectivity alloys.
• The FurnaceLine is a large clearance sensor intended for monitoring levels inside
melting and holding furnaces.
• The LaunderLine is a medium clearance sensor intended for monitoring levels in
troughs and launders for general metal transport and DC casting.
• The CastLine is a small to medium clearance sensor intended for level control in DC
casting lines.
• The ContinuousLine is a medium clearance sensor intended for monitoring levels in
continuous caster headboxes.
• The DeltaLine is a small clearance sensor with the capacity to measure the true
metal level relative the mould in DC casting lines.
A variety of clearance distances and measurement ranges are available within each
application group.
The Selcom XLine sensors can be delivered as a complete unit, including a heat-insulated
protection box with a mounting bracket, an integrated cable in a steel conduit and a
heavy-duty industrial connector.
It is also possible to purchase the sensors as stand-alone units for customers with special
demands on mounting and systems integration.
Optional accessories are integrated exchangeable protection glasses and glass holders.
All Selcom XLine sensors intended for use in operator accessible areas are rated FDA
Class ll, IEC60825-1 Class 2, meaning that no special, laser safety user precautions are
required.
All Selcom XLine sensors carry the CE label meaning that they comply with applicable
parts of the EMC directive of the European Union.
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All Xline sensors operate on the principle of laser triangulation. A semiconductor laser
directs a laser beam with tightly specified properties onto the target. A “viewing” part of
the sensor images the light pattern onto an image detector and the position of this image
on the detector contains the basic information on distance to the target.
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2 LASER SAFETY
2.1 Safety precautions
The light source of the Selcom XLine is a semiconductor laser emitting visible light.
The Selcom XLine has a 2, 3R or 3B classification (depending on model) according to:
IEC 60825-1 Safety of Laser products and complies also with FDA performance
standards for laser products except for deviations pursuant to Laser Notice No. 50, dated
July 26, 2001.
If otherwise strykes not explicitly stated, always disconnect the power supply unit during
installation, service and maintenance of the Selcom XLine sensors.
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2.2 Classification
the blink reflex, the wavelength must be in Complies with FDA performance
requirements and control measures for users IEC 60825-1:2001 for deviations pursuant to Laser Notice
No 50 dated July 26, 2001
AVOID EXPOSURE
laser
radiation emitted
from this aperture
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The specific user precautions as specified in IEC60825-1 and relating to the different
laser classes are:
CastLine
LaunderLine
FurnaceLine
ContinuousLine
DeltaLine
Key control Not required Not required Remove when not in use
The table above shows that all CastLine, LaunderLine and DeltaLine sensors can be
used throughout the foundry without any special requirements. This does not preclude
general caution and the need to avoid continuous direct beam viewing for times
exceeding 0,25 sec. (blink reflex).
The requirements for Class 3A/3R and 3lllB/3B are valid for FurnaceLine sensors when
operated dismounted from the furnace as may be the case during installation and service.
If the need exist to operate the sensor during such conditions, all user precautions as
stated must be followed.
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3 SENSOR CONNECTIONS
3.1 General
The sensor is equipped with a 0,5 m cable with a 25 pin male D-sub connector.
The connector type used provides proper connection of the cable screen. The plastic
connector cover avoids problems with unintentional grounding of the sensor.
Sensors provided with a Heat shield and cable kit solve this by incorporating a protected
cable ending in a heavy-duty industrial connector. The delivery includes a mating
connector with screw terminal connection of the customer cable.
User’s building their own protection system may order extension cables with various
lengths from LMI Technologies. Such extension cables are of the same high quality,
temperature resistant type, as the pigtail coming out of the sensor.
The extension cables are fitted with an identical, isolated cover and screen grounding,
D-sub connector as mounted on the sensor pigtail.
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This specification
defines all possible and Pin nr. Signal type
common connections
to sensors in the Xline 1 Power (+24 VDC)*
family. Application
2 Power (+24 VDC)
specific use of these
connections are possible 3 Power ground
and in such cases 4 Power ground
these connections are 5 Analog out 1+ (metal level+)
specified under “Sensor 6 Analog out 1- (metal level-)
specification”. For
7 Analog out 2+
connections using the
heat shield and cable 8 Analog out 2-
kit refer to chapter 7 9 Analog out 3+ (temperature+)
(Installation). 10 Analog out 3- (temperature-)
11 Digital input 1+
* Note: Power and 12 Digital input 1-
power return are
13 Digital input 2+
“doubled” in the
connector to allow 14 Digital input 2-
for high AWG cable 15 Digital output 1+ (Valid level signal+)
types to be used. It is 16 Digital output 1- (Valid level signal-)
not required to supply 17 Digital output 2+
voltage/return to all
18 Digital output2-
power/power return
pins. 19 RS232 (Ground)
20 RS232 (Receive data)
21 RS232 (Transmit data)
22 Not used
23 Laser on (+24 VDC)
24 Not used
25 Not used
Connector Cable screen
housing
13 1
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Laser control input: This control input should be held at +24 VDC (18-32 V) @ 50
mA(max) to enable the laser.
Analog output: The Selcom XLine analog output channels are 4-20 mA current loop
outputs. A separate loop return path is provided for each output in the sensor connector.
It is also possible to allow loop return to the power supply ground (pin 3 and 4) in order
to minimize cable leads.
Analog output load restriction: The maximum load resistance, incl. Cable resistance,
should be limited to Req=(Supply voltage-2V)/20 mA. For most applications it is
recommended to limit the load resistor to 500 Ohm (=2-10V).
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The standard factory calibration always places the 20 mA position at CD and the 4 mA
position at CD+MR.
CD and MR of the delivered sensor are found on the serial no. label. The currently
available CD/MR combinations are also listed in the application specific part of this
manual.
Refer to chapter 4 : Support Software “Aluminium Level Analysis (ALA) “ for detailed
use of this function.
Holding the analog level output at the latest good signal avoids letting erroneous data
enter the controller.
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The Selcom XLine has a built in temperature sensor that is provided over analog output
channel 3.
The analog temperature signal should be used to monitor the sensor cooling and to set
alarm levels for exceeded sensor temperature.
The Selcom XLine has an “Valid level signal” that is provided over Digital output
channel 1.
The digital outputs are opto-coupled transistor outputs that allow the user to arrive at
different signal polarities and levels depending on the input demand of the control system.
A typical PLC input connection scheme is indicated below. The 4,7 kOhm resistor at the
PLC input is required to provide a current return path to the +24 VDC supply ground.
The output transistor is conducting during normal (valid) operation meaning that the PLC
input as connected below is “high” and goes “low” during Invalid conditions.
25 pin D-sub
15
+24 VDC
+24 VDC
digital input
4,7 kOhm
16
0V
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The software package Aluminium Level Analysis (ALA) is a support software package for
operation in a user supplied external PC that allows sensor users to perform a number of
useful tasks during installation, normal production and trouble shooting.
4.2 Installation
The ALA can be installed and run on PC’s with Windows 98 and up. The physical
connection requires one available com port.
The ALA1.0 communicates with the sensor over a standard RS232 serial link i.e. a simple
3-wire cable is required between the PC’s com port and the designated RS232 pins in the
sensor connector.
19 5
20 3
21 2
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Connecting
Start ALA by double clicking the program icon.
With the sensor connected and powered on, choose the correct COM port from the pull
down menu in the settings window and press “Connect”. The red indicator should turn
green to indicate that connection to the sensor is established.
Diagram window
Clicking “Save to log” before “Start” will enable a recording session and the user is
prompted to enter a file name. A stored data file can be opened and played back by
pressing the “Playback” button and selecting a file. The playback is done in real time.
Pressing “Save to Excel” with a log file open will create a text file organized as tab-
separated columns. This text file is easily opened and manipulated in Microsoft Excel.
Pictures in .jpg format of the main window and side window can be stored by pressing
the “Save Picture” button.
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Main window
The Main Window shows a
white outlined rectangular
region, centrally placed
in the window. The width
and height of the indicated
region correspond with the
image area required for the
line length and measurement
range of the specific sensor
type.
When changing the distance between sensor and target, the red pixel line will move up
and down in the region. Moving up in the region indicates a closer distance and down a
longer one.
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Side window
The side window to the left of
the main window is a qualitative
indicator from the output of the
proprietary line-identifying image
processing algorithms.
Note: changing the scaling does not influence the sensor or the measurement and can be
done at any time.
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Measurements window
The measurements window
provides numerical data from
the sensor.
• Distance:
The distance between sensor
front and target in mm’s.
• Distance as analog:
A “synthetic” mA-value that is a
very close indicator of the expected
value on the “real” analog current
4-20 mA loop output.
• Exposure:
The exposure time used to create
the images used for distance
measurement. Shorter times
(<1000 us) indicate a diffuse and/or bright surface. Longer times (>1000 us) indicate a
shiny surface.
• Sensor temperature:
The internal sensor temperature in degrees C.
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Version window
The version window
provides information on
serial number and FPGA/
Firmware revision status.
The software capability
of the sensor may be
remotely upgraded from
the same PC as runs the
ALA.
Diagram window
The diagram window
visualizes the data logging
functionality.
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Set-up menu
Pressing the “Setup” button will
open a separate terminal emulation
window that allows access to
internal sensor settings.
• Averaging : 10
• 4 mA set point: CD+MR
• 20 mA set point: CD
Close the terminal window by pressing the X-button in the upper right corner.
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Measurement
range (MR)
4 mA
Averaging setting
The setting of the averaging parameter may be used to simulate the response time
characteristics of other types of sensors to be replaced. It is also possible to smoothen
short term variations or vibrations that may occur in some processes.
Note: The setting of the averaging parameter will influence readings on the ALA screen
and analog outputs used for control purposes in the same way.
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The region for grey-scale image read-out is set with the mouse. Press the left button to set
one corner of the region and release it at the desired second corner.
The exposure time for the snap-shot is set manually and entered in the Exposure box.
Time is entered in microseconds in the range 10 – 60000 us.
Pressing Start and choosing Yes on the following question will start the image read-out.
The read-out image can be threshold or colour coded and the image can be saved by
pressing the Save Picture button.
Limiting coordinates
of chosen Region
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5 SENSOR SPECIFICATION
5.1 LaunderLine specification
CD
20 mA
MR
4 mA
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5 SENSOR SPECIFICATION
5.2 Identification of parts
Side view
Manufacturers serial
Laser emitting number label Warning label
label
LASER RADIATION
AVOID EXPOSURE
MAX POWER: 5 mW
EMITTED WAVELENGTH: 635-670 nm
laser
Front view
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5.3 Dimensional
Side view
70
70
70
70
Front view
350
350
223,3
223,3 72
72 35
35
18,5
18,5 16
16
56(2*)
56(2*)
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A complete Heat Shield consists of a few parts that need to be ordered separately. The
heat shield will be assembled if parts are ordered together on the same PO.
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Standard version
809925 Mating connector kit 16p,
for Selcom Heatshields
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400
400
390
390
346
115
115
130
143
143
170
170
198
198
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7 INSTALLATION
7.1 Mounting of Launderline sensors
The long clearance distance (700 mm alt. 1500 mm) of the LaunderLine sensor makes the
mounting of the sensor over the launder a less complicated task.
The long distance to the hot metal and the protective heat shield effectively reduces any
influence from radiated heat on the sensor.
Mounting structure
A double leg mounting stand is
more stable compared to a singe
leg stand.
Avoid occlusion
in deep launders by positioning
the sensor along the launder
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Sensor tilts
The LaunderLine may be side tilted
up to +/- 30 degrees to facilitate
mounting
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Sensor Height
Position the sensor so that
the bottom of the launder and
the highest expected metal level
are within the sensor MR
CD
MR
30 degrees
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-
+24 VDC / 1A
+
+24 VDC 4-20mA PC/Laptop
Digital input Analog inputs RS232
valid - + + 5 3 2
Laser power 13
switch 14
Electrical cabinet
Mating connector 14 12 15 8 11 7 13 10 2 1 9
25pin DSUB
connector 23 15 1 16 3 6 5 9 19 20 21
(inside heatshield)
Laser Valid + +24 VDC Valid 0V Analog - Level Temperature RS232
on
XLine Laser Sensor with Heat Shield
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8 MAINTENANCE
8.1 Replacing a sensor
3. Insert a 6 mm Allen
key into the small hole
and untighten the screw
a couple of laps.
Remove the sensor and
disconnect the 25pin
DSUB Connectors.
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10 LMI CONTACTS
LMI Technologies Inc. is a worldwide supplier of non-contact laser sensors and systems
for improved quality and productivity in industrial applications.
North America:
LMI Technologies (USA), Inc.
21455 Melrose Ave., Suite 22
Southfield, MI 48075
USA
Phone: +1 (248) 359-2409
Fax: +1 (248) 355-3283
E-mail: [email protected]
USA East: +1 (770) 888-6586
Europe:
LMI Technologies bv
Valkenburgerweg 223
6419 AT Heerlen
The Netherlands
Phone: +31 45-5719300
Fax: +31 45-5742500
E-mail: [email protected]
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