Prime Controls

Prime Controls manufactures Double Sheet and Blank Detectors for the metal industry.

The top canmakers, appliance and car companies use PRIME Double Sheet Detectors.

Prime Controls Pulser

NEW! Prime Controls Introduces New
Single Probe Double Sheet Detector

Prime Controls, Inc. has introduced a single probe double sheet detector that can operate in locations where space limits the use of dual probe detectors. 

The Pulser Double Sheet Detector features a newly-designed single probe with a pulsed electromagnet that quickly samples ferrous metal sheets without holding on to them like previous single-probe detectors that used permanent magnets. 

In addition, the Pulser is able to detect sheets that are 30% thicker than comparable double sheet detectors, which makes it usable in more types of steel sheet feeding applications...MORE

The Pulser Double Sheet Detector consists of a sensor probe and a control unit.  Four models of Pulser probes are available with different diameters and magnet strengths to detect metal thickness from as little as .25mm (0.01”) up to a maximum of 6.4mm (0.250”).  The sensor probes are ruggedly constructed of stainless steel and have a built in metal proximity detector, which allows the detector to turn-off after thickness measurement, count sheets and/or detect that the last sheet has advanced.  The DS200 control unit features simple one-button calibration that automatically measures the thickness of a sample sheet, calculates the double thickness value and sets the reject threshold.  An optional two sample calibration process allows the control unit to detect and respond to variations in metal thickness as small as 5%.

Located in Dayton, Ohio, Prime Controls is a world leader in sensors for double sheet metal detection, metal thickness and container leak monitoring.  Prime Controls’ metal sensors can be found in canmaking, automotive, appliance and other metal forming facilities around the world.

Prime’s Model DS200 Single Probe Double Metal Sheet Detector is installed in difficult locations where sensing is only possible on one side. It detects ferrous metals over a thickness range of .25 mm to 6.0 mm (.01” to .240” ). The DS200 measures the change in it’s magnetic field as metal is in contact with it's face. A new sensing element in the probe head increases sensitivity and improves stability compared to other brands. To calibrate, simply insert a sheet in front of the probe and push the calibrate button. The detector automatically sets the reject threshold above the single sheet reading. It’s form “C” contact relay de-energizes if a double is detected, power is lost or a probe failure is detected. One additional PNP transistor output turns on when metal is detected. This metal output is applied (including doubles) to a good sheet counter, jam detector or last sheet detect circuit. The Model DS200 detector has fault detection that immediately analyzes any problem and operates a blinking Green LED code that directs the operator or maintenance department to the problem.



Model DS200 - Double Metal Sheet Detector

  • Pulsed Electromagnetic
    does not hold on to metal blank or sheet
  • Single metal thickness ranges
    .25 mm to 6.0 mm (.01 “ to .240”)
  • Four Probe Diameters
    36mm, 42mm, 54mm, 75mm
  • Metal Present Output
    transistor (PnP) output when metal present
  • Proximity Detector
    built in proximity probe to detect metal, last sheet
  • Push-Button Calibration
    instantaneously measure thickness, calculates reject threshold
  • Teach
    with a single sample or two sample,
  • Fast Response to Double Detection
  • Diagnostic Warning
    alternately flashing lights for error and probe failure, fail safe output
  • Power Input
    Range 100 to 240 VAC @ 50-60 Hz 20 w
    Quick Connect
    terminals for fast replacement and to reduce downtime
  • Contact Relay output rated at 10 AMPS (½ HP) @240VAC, 8 AMPS @24 VDC.
  • Works with all Prime PE Model probes


Power input:

Ranges from 100 Volts to 240 Volts AC Max, 50 to 60 Hz, at 20 Watts

Output Response < 140 mSec. w/PE36 to <250mSec w/PE75
Outputs: SPDT contact relay Double detected, NC closed Max. load 10 Amps @ 240 Vac, 8 Amps @ 24 V dc ½ HP @ 240 V ac
Metal Present Output:

PNP transistor, sourcing 24 Volts dc, 100mA max.
Metal detected= 24 V dc,
No metal = 0 V dc

Output fail Safe: Contact goes to double condition. Metal Present output turns off, indicating no metal present.
Metal Sensitivity: Ferrous metal, steel, tinplate
Calibration: Push-button switch with single sheet or two sample teach for fine accuracy
Sample Indicators: Green for single, amber for double, green blinking probe is bad or disconnected
External inputs: Calibrate & output latched reset
Sensor Operation: magnetic flux field generated by a quick electromagnetic pulse is shunted across sensor poles by the thickness of metal. Maximum thickness is limited by the diameter of the probe. The chart below provides a range for each probe.
Probe Model
Probe Diameter

Breakaway Force

Min. Thickness
Max. Thickness
36mm (1.42")
<1 lb.
0.25mm (.01")
2.3mm (0.09")
42mm (1.65")
<1 lb.
0.25mm (.01")
3.6mm (0.14")
54mm (2.13")
<1 lb.
0.25mm (.01")
4.6mm (0.18")
75mm (2.95)
<1 lb.
0.25mm (.01")
6.0mm (0.24")


prime controls Pulser probe

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Manufacturing Solutions, Inc. - Corporate Ofice
P.O. Box 427
Lawrenceburg, TN  38464
Office:  (931) 762-8773
Fax:  (931)766-0083

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