Dust-Extreme detection unit upgrade kit
The XIAC Dust-Extreme detection unit is a direct replacement upgrade for Cremer CF1220 and CVC1220 machines. It is engineered for heavily dust-producing products where signal margin gradually collapses in aging OEM detection systems.
Dust-Extreme boards are designed with increased dynamic range so the LED drive can compensate for greater optical attenuation over time. The result is longer stable operation and fewer cleaning interruptions — without changing the machine interface, outputs, or operating workflow.
From the operator’s perspective, the system behaves as expected — improved stability is achieved internally.
OEM-compatible outputs and Cremer OEM serial protocol — designed to drop into the existing detection unit ecosystem.
OEM software compatibility
Compatible with CF1220 / CVC1220 machines running OEM detection unit software version CF1220VE. After installation, the OEM HMI will report detection unit software version CF1220VX.
All other HMI behaviour remains unchanged (for example, the reported channel voltage format remains identical, e.g. 3.51 V).
Outputs & communications
- OEM-compatible outputs: 12 channel outputs; 1 product-too-long output; 1 double-detect output.
- Serial communication: Cremer OEM protocol (drop-in compatible).
- Mechanical inserts: Supports all available OEM CF1220 channel inserts (e.g. 20 mm, 16 mm, etc.).
Kit contents
The Dust-Extreme upgrade kit consists of four coordinated boards supplied as a matched set. All boards are designed as direct replacements for their respective OEM counterparts.
| Board | XIAC part number | Replaces OEM board(s) | Notes |
|---|---|---|---|
| Emitter board | 2050401 | 950203, 2010201, 2050401 | Higher dynamic range LED drive |
| Detector board | 960701 | 950202, 960701 | Improved signal stability under attenuation |
| Connector board | 950702Xv1r4 | 950702 | Maintains OEM harness & interface format |
| Processor board | 2230402v1r1 | 960701, 980402 | Supplied with ribbon cable |
Installation
The Dust-Extreme kit is designed for field installation and service environments. Typical installation time is less than 2 hours (including cleaning and inspection).
- Direct mechanical fit: screw positions and connector locations are identical to OEM.
- No wiring changes: integrates into the existing OEM setup.
- No PLC or HMI modification: retains the existing machine ecosystem.
Also resolves common aging OEM detection faults
While Dust-Extreme is primarily designed to maintain reliable detection under heavy dust load, it is also an effective upgrade path for many common faults seen in aging OEM detection units.
- Channel defect errors (intermittent or persistent)
- Product-too-long / overlap events followed by channel defect
- Occasional undercounts that cannot be traced to product flow or mechanical causes
- COM2 defect communication faults
These symptoms often appear gradually as electronics and the optical path age. Dust-Extreme restores stable signal margin and maintains OEM-compatible communication behaviour without changing the machine interface.
Key features
- Increased dynamic range to compensate for greater dust accumulation over time
- Reduced cleaning frequency compared to standard detection electronics under heavy dust load
- OEM-compatible outputs (12 channels + product-too-long + double-detect)
- Cremer OEM serial communication protocol
- Supports all OEM CF1220 channel inserts (e.g. 16 mm, 20 mm, etc.)
- Direct mechanical fit into the OEM detection unit (identical screw and connector positions)
- Fast installation (typically < 2 hours including cleaning)
Alternative option: Dust-No-Problem detection kit
If the primary objective is to resolve faults caused by aging OEM detection electronics — such as channel defect errors, product-too-long events followed by channel defects, occasional undercounts, or COM2 communication faults — the Dust-No-Problem kit is often the more economical choice.
Dust-No-Problem is architecturally similar to the Dust-Extreme kit and maintains full OEM compatibility. It restores stable detection behaviour with a moderate dynamic range extension suitable for standard dust environments.
- Direct mechanical replacement
- OEM-compatible outputs and Cremer serial protocol
- Restores signal margin lost due to aging electronics
- Optimised for standard production conditions
After installation, the OEM HMI will report: Detection Unit Software: CF1220VF
When extreme dust tolerance and extended cleaning intervals are not required, Dust-No-Problem provides a cost-effective and robust replacement solution.
Diagnostic Reference: OEM Detection Unit Fault Analysis
The following video demonstrates typical diagnostic procedures for aging OEM detection units used in CF1220 and CVC1220 machines.
Recurring channel defects, product-too-long events, undercounts, and COM2 faults are often linked to aging detection electronics and reduced optical signal margin. The Dust-Extreme upgrade addresses these root causes while maintaining full OEM protocol compatibility.