1 Operating Instructions Controller wms-4/4i II for the ultrasonic sensors of the wms series *B2885*
2 Front panel Legend LED»OFF«LED»ON«1»UP«button 2»DOWN«button 3»ENTER«button 4 Green LEDs»NEAR/FAR«5 Green LEDs channel characteristic 6 Slider switch»scan/sync«7 Green LEDs for type of sensor 8 Yellow LEDs for indicating channel Fig. 1: Dimensions Fig. 2 Controls and LEDs showing sensors connected 2
3 Contents Contents 1 Description of unit Important advice concerning installation and use Installation Setting-up Operation Normal mode Setting up the reference channel (option) Programming a channel of the controller Copying settings Activating/Deactivating a channel Technical Specification Indicator mode Optional SHIFT mode Programming
4 Description of unit 1 Description of unit Please refer to the technical specification for details of the controller and the wms series data sheet for details of the sensors. The wms-4/4i II controller is designed for connecting up to four ultrasonic sensors of the wms series. The sensors are controlled and signals evaluated centrally in the contro l l e r. There f o re, only the robust sensors (all complying with class of pro t e c- tion IP 65) are subjected to the (sometimes) tough conditions of the working enviro n m e n t. The controller (class of protection IP 20), which c o n t rols the sensors and evaluates the signals, is accommodated safely in an electrical cabinet. 4 The analogue signals are determined by ultrasonic measurement in the controller. The sensor emits a brief sound pulse (see Fig. 3). This pulse propagates in the air and is reflected back from an object as an echo. The wms-4/4i II measures the time taken between emitting the signal and receiving the echo. From this propagation time, the controller determines an analogue signal proportional to the distance (rising: ma, or falling: ma). Fig. 3: Ultrasonic measurement
5 Description of unit Fig. 4: Analogue signal proportional to distance 5 Various wms sensors can be operated by one device. The controller can control the wms sensors either simultaneously (synchronous mode) or successively (scan mode or multiplexmode). The choice of operating mode (selected by way of a slider switch on the front, see Fig. 2) depends on the application. Very precise distances or thicknesses can be measured by combining the controller with the appropriate wms sensors (e.g. wms-25/rt/hv M18, see Fig. 5). The controller offers users the option of using one sensor channel for temperature compensation. The sensor connected to this channel measures the distance to a fixed target. The measured values of the other sensors are then compensated by the value of the»reference sensor«(see Fig. 6). Further, the average current value of the other, active channels is output at the reference channel output. The analogue windows set for all active sensors can be moved simultaneously and identically via the»shift«input. This option requires the addition of an external circuit consisting of one special switch (see»optional»shift«mode«) and two resistors.
6 Important advice concerning installation and use 2 Important advice concerning installation and use The wms-4/4i II is one component within a control system! During installation, setting-up or maintenance work, all measures must be taken to ensure safety of personnel and plant (refer to operating instructions for complete plant and instructions of plant operator). Fig. 5: Possible application: conveyor belt with measurement of width and height 6 Fig. 6: Possible application: film extruder with reference channel Hazards can arise from substances and materials being processed in the plant! Take all necessary precautionary measures and wear suitable protective clothing (adhere to directives of employers liability insurance association as well as instructions of plant operator or plant operating instructions).
7 Important advice concerning installation and use The controller is not intended for use with systems serving the safety of persons or security of machines! The operating instructions make use of the following keywords: Danger health hazard or risk of injury Caution important information regarding the safe operation of equipment Warning risk of severe damage to equipment, machinery or the environment Note advice concerning rational operation or special aspects which have to be taken into account Before you attempt to intervene in the operation of the controller, carry out a risk analysis with regard to the repercussions of: failure of controller failure of sensors failure of temperature compensation set-up incorrect control commands (e.g. when programming the controller) In doing so, take into account not only the immediate risks for personnel and plant but also the effects on the local environment! Danger! Ignoring the following instructions can result in a risk of injury to yourself or others or damage to property. Only operate the plant when you have sound knowledge of its operation and control. If necessary, ask the operator s specially trained personnel to assist you. Switch the plant to a safe condition (e.g. switched off, creep mode). For details, refer to the operating instructions for the complete plant. Take all precautions to ensure that this safe condition cannot be changed while work on the system is being carried out (e.g. actuate key-operated switch). 7
8 Installation Take all prescribed industrial safety measures (adhere to directives of employers liability insurance association as well as instructions of plant operator or plant operating instructions). 3 Installation The controller is intended to be mounted in a protective housing (e.g. distribution cupboard, electrical cabinet), and attached to a top-hat rail conforming to DIN EN Warning! All installation work must be carried out by a qualified, competent electrician. Caution! The voltage supply for the sensors is provided by the wms-4/4i II controller. Never connect the sensors to any other external voltage supply. The connections for sensor voltage supply are protected against reversed polarity but not against short-circuits! A short-circuit can lead to considerable damage to the electronics. Ensure that the controller is installed in a wellventilated position to keep it cool during operation (see»technical Specification«). The operating environment for the controller must be dry and dust-free (class of protection IP 20). The sensor cables must not be more than 25 m long. All cables longer than 5 m should be shielded. 8
9 Installation Place the controller on the top-hat rail at the desired position and clip it onto the rail using light pressure. If required, install sensor and target for reference measurement (e.g. for temperature compensation). Attach the sensors to the screw terminals for inputs (see Fig. 2). The wms-4/4i II can be operated with 1, 2, 3 or 4 sensors. 9 The following types of sensors can be operated simultaneously with the controller: wms-25/rt/hv/m18 wms-30/rt/hv/m30 wms-101/rt/hv/m30 wms-301/rt/hv/m30 wms-601/rt/hv/m30 Fig. 7 Sensor selection table If you are using microsonic connecting cables, note the colour coding of the wires. Terminal Colour Pin-No. on unit S e n d e r / S e n s o r white 2 U0/Sensor brown 1 Echo/Sensor black 4 GND/Sensor blue 3 Fig. 8: Colour coding and view of pins on wms-type sensor
10 Setting-up If required, connect a»shift«switch to the»shift«screw terminal via the two external resistors according to the following diagram: Fig. 9: Connection diagram for»shift«switch Danger! The controller starts operating immediately once the voltage supply is switched on. This could result in undesirable control commands leading to hazards for persons and plan. Switch off the plant or only connect the cables to terminals»output 1...4«after the controller has been properly programmed (see»setting-up«). Lay the cables for controlling the plant as far as the controller. Connect the controller to the low-voltage supply ( V d.c.) via screw terminals +UB and -UB. 4 Setting-up All setting-up operations (e.g. initial set-up or after modifications/repairs) must be carried out by suitably trained, competent persons! The settings of the controller must be checked or the controller fully programmed during every setting-up procedure. The wms-4/4i II is preprogrammed as follows before being dispatched: all sensor channels ON sensor type wms-101/rt/hv/m30 sensor local window limit 190 mm sensor remote window limit 340 mm rising output characteristic synchronous mode 10
11 Setting-up Danger! The controller starts operating immediately once the voltage supply is switched on. This could result in undesirable control commands leading to hazards for persons and plant. To carry out accurate programming of the device or to check the settings you will need a measuring instrument (e.g. ammeter) for the output currents of the controller s sensor channels. Observe the foregoing warnings and safety instructions when attaching the measuring instrument! Note The connections for the voltage supply to the controller incorporate reverse polarity protection. If the controller or the sensors supplied via the controller do not function correctly, check the polarity of the connections for the controller s voltage supply and the connections of the sensors at the controller. Switch on the voltage supply to the controller. The controller and its associated sensors are opera - ting correctly when the green LEDs (Fig. 2, Pos. 7) of the active sensors light up in a cycle and hence indicate normal measuring mode (see»normal mode«). 11
12 Normal mode Check the settings or reprogramme the controller. To do this, refer to»programming«. 5 Operation The wms-4/4i II controller can operate in the following modes: normal mode indicator mode»shift«mode 5.1 Normal mode Indication of measuring activity All active sensor channels indicate measuring activity by way of a flashing green LED (Fig. 2, Pos. 7). Function of channel LEDs If there is an object within the detect range of a sensor, then the sensor s associated yellow LED (Fig. 2, Pos. 8) lights up. 12
13 Indicator mode Selecting the operating mode The controller may be switched between two operating modes at any time. To do this, switch the»scan/sync«slider switch (Fig. 2, Pos. 6) accordingly.»sync«: switches the unit into the synchronous mode. All sensors are controlled and evaluated simultaneously.»scan«: all sensors are controlled and evaluated in succession. This mode allows, for example, opposing sensors to be operated. Please note that the measurement repeat rate of each individual sensor is lower than for sync mode. 5.2 Indicator mode The unit s settings can be indicated at any time in normal mode. The normal operation of the controller does not have to be interrupted. Briefly press the»up«or»down«button (Fig. 2, Pos. 1 or 2). This selects the indicator mode. The following information is provided for one channel (see Fig. 10): number of channel indicated channel characteristic type of sensor Sensor channel (yellow LEDs, Fig. 2, Pos. 8) Type of sensor (green LEDs, Fig. 2, Pos. 7) wms-25/rt/hv/m18 wms-30/rt/hv/m30 wms-101/rt/hv/m30 wms-301/rt/hv/m30 wms-601/rt/hv/m30 Characteristic of sensor channel (green LEDs, Fig. 2, Pos. 5) rising ma falling ma reference channel 13 Fig. 10 LEDs on controller
14 Optional»SHIFT«mode Briefly press the»down«button to switch to the next sensor channel or the»up«button to switch to the previous one. Briefly pressing both buttons simultaneously switches the controller back to normal mode. The unit automatically returns to the normal mode 20 s after the last button is pressed. 5.3 Optional»SHIFT«mode This operating mode allows the window limits for the output of analogue values to be modified. Consequently,»SHIFT«mode is suitable for the fine calibration of sensors and control, e.g. during a plant test run. This operating mode is an optional feature. To enable this function, a special switch must be installed (see»installation«). This switch has three positions:»upoffdown«all window limits for the output of analogue values are moved in the same direction (»UP«or»DOWN«). You can make small changes by briefly moving the switch to»up«or»down«or larger changes by holding the switch in one of these positions. The preset window size remains constant. The windows can be moved until they reach the preset limits of the sensors. The speed at which the windows are moved depends on which mode»scan«or»sync«has been set (»SCAN«= slower shift than»sync«). 14
15 Optional»SHIFT«mode Danger! The operation of the controller is not interrupted during»shift«mode! All changes take effect immediately. This could result in undesirable control commands leading to hazards for persons and plant. Move the»shift«switch into the»up«or»down«position (briefly and then releasing it or by holding it in position). The preprogrammed windows for the output of analogue values are changed for all active sensors.»up«= moving away from sensor»down«= moving towards sensor The direction of the movement is indicated by the flashing green LEDs»NEAR«(= down) or»far«(= up) on the front of the controller. At the same time, the channel indicator LED flashes for the channel which is being adjusted. Release the»shift«switch. The new values for the window limits local to and remote from the sensor are stored in the EEPROM. The controller returns to the normal mode. 15
16 Programming 6 Programming The programming feature enables settings to be made so that the controller s program can be adjusted to the actual measuring and control requirements of the application. The following settings are possible: (complete) programming changes to programmed settings copying of settings activation/deactivation of channels Programming (e.g. initial set-up or after modifications/repairs) must be carried out by suitably trained, competent persons! Danger! The operation of the controller is not interrupted during programming! All changes take effect immediately. This could result in undesirable control commands leading to hazards for persons and plant. Warning! If the plant cannot be shut down completely, then the connection between plant control and wms controller may only be interrupted when no undesirable control commands would result from such an interruption. Take all necessary measures to ensure safety of persons and plant (see»important advice concerning installation and use«). The exact settings of the analogue windows (position and size) can be made and checked with an ammeter. Observe the foregoing warning and safety instructions when attaching the measuring instrument! 16
17 Programming The following points apply to the procedure: Individual programming steps may be skipped. Briefly press the»enter«button. This switches to the next step and existing settings are not altere d. An incorrect entry can be corrected by waiting 20 s. Provided no button is pressed during the 20 s, no changes are stored and the unit automatically returns to normal mode. Settings and changes are only accepted when the programming procedure has been completed or the copying of settings has been completed. Note the various functions of the»enter«button: In normal mode, press»enter«for approx. 3 s in order to initiate the channel selection (one yellow channel LED flashes). Briefly press»enter«in order to confirm a selection/setting and to switch to the next programming step. Press»ENTER«for approx. 5 s in order to copy settings to the other active channels (see»copying settings«). Note If you wish to use one sensor channel for temperature compensation, you must first set up this channel as a reference channel before programming the other sensor channels. 17
18 Setting up the reference channel (option) 6.1 Setting up the reference channel (option) Initiating the programming Press the»enter«button until one of the yellow channel LEDs (Fig. 2, Pos. 8) flashes (after approx. 3 s). Briefly press the»enter«button. Entering the type of sensor Select the type of sensor connected to the reference channel by pressing the»up«or»down«button. Selecting the channel characteristic»ref«select the channel characteristic»ref«by pressing the»up«or»down«button. Both channel characteristic LEDs (Fig. 2, Pos. 5) must flash. =»REF«Release the»enter«button. Selecting the reference channel Select the reference channel using the»up«or»down«button. The yellow channel LEDs (Fig. 2, Pos. 8) indicate the channel selected. 18 The green LEDs (Fig. 2, Pos. 7) indicate the type of sensor. (If all LEDs flash, then this shows that the sensor channel has been deactivated.) Briefly press the»enter«button. Setting up the reference channel Briefly press the»enter«button. The wms-4/4i II now stores the current distance to the reference target. The arithmetic mean current value of all the other active channels is output at the analogue output of the reference channel. (In the case of thickness gauging with two sensors plus one reference sensor, the value of the current at the
19 Programming a channel of the controller reference channel now corresponds directly to the measured thickness.) The settings for the reference channel are copied into the EEPROM of the controller and stored permanently. The controller immediately returns to normal mode. You should now set the other sensor channels. 19 Note If there is no valid echo time present in the analogue window set for the reference channel, the programming procedure stops at this point until a valid measurement is available; until no button is pressed within 20 s. If another channel was previously the reference channel, then this now becomes a»normal» channel. Its settings type of sensor, channel output characteristic, position and size of analogue window remain unchanged. 6.2 Programming a channel of the controller The programming is carried out separately for each channel of the controller. The window sizes can be set manually or copied at the press of a button (»teach-in«). Note The minimum width of window is 50 mm. If this width is reached, then the other window limit is moved 50 mm ahead of the limit to be adjusted until the maximum range or the blind zone of the sensor is encountered (see Fig. 4). If there is no target within the beam spread during teach-in, then the local sensor limit is set 50 mm short of the maximum range or the remote sensor limit is set to the maximum range.
20 Programming a channel of the controller Abb. 11: Variable window limits Initiating the programming Press the»enter«button until one of the yellow channel LEDs (Fig. 2, Pos. 8) flashes (after approx. 3 s). Release the»enter«button. Largest window Smallest window limit remote from sensor 20 limit close to sensor wms-25/rt/hv/m18 35 mm 350 mm wms-30/rt/hv/m30 65 mm 600 mm wms-101/rt/hv/m mm mm wms-301/rt/hv/m mm mm wms-601/rt/hv/m mm mm Selecting a channel Select the channel to be programmed by pressing the»up«or»down«button. The yellow channel LEDs (Fig. 2, Pos. 8) indicate the channel selected. Briefly press the»enter«button. Entering the type of sensor Select the type of sensor connected to the channel input by pressing the»up«or»down«button. The green LEDs (Fig. 2, Pos. 7) indicate the type of sensor selected. (If all LEDs flash, then this shows that the sensor channel has been deactivated.) Briefly press the»enter«button. Selecting the channel characteristic Select the channel characteristic by pressing the»up or»down«button. The green channel characteristic LEDs (Fig. 2, Pos. 5) indicate the chosen characteristic:»rising«( ma) or»falling«( ma) Briefly press the»enter«button. Setting the local window limit The green LED»NEAR«flashes (Fig. 2, Pos. 4).
21 Programming a channel of the controller Move the object to be scanned or a temporary target to the position at which the local limit of the analogue window is to be set. Press the»up«and»down«buttons simultaneously. The controller accepts the current distance to the target as the local window limit (»teach-in«). Or adjust it manually: Press the»up«or»down«button. The local limit is moved away from the sensor with the»up«button, towards it with the»down«button. Check the setting with an ammeter if necessary. Note You can adjust the limit step by step (press briefly) or continuously (hold down). Briefly press the»enter«button. Setting the remote window limit The green LED»FAR» flashes (Fig. 2, Pos. 4). Move the object to be scanned or a temporary target to the position at which the remote limit of the analogue window is to be set. Press the»up«and»down«buttons simultaneously. The controller accepts the current distance to the target as the remote window limit (»teach-in«). Or adjust it manually: Press the»up«or»down«button. The remote limit is moved away from the sensor with the»up«button, towards it with the»down«button. Check the setting with an ammeter if necessary. Note You can adjust the limit step by step (press briefly) or continuously (hold down). 21
22 Copying settings Briefly press the»enter«button. Only now are all the settings copied into the EEPROM of the controller and stored permanently. The controller returns to normal mode. If necessary, set further sensor channels. To do this, return to»initiating the programming«. 6.3 Copying settings This program function of the controller eases the task of programming several channels of the controller. All the settings are copied to the other channels of the controller. A number of points must be taken into account: The copying of settings is only possible when the active sensors are all of the same type. No settings can be copied from a (temperature) reference sensor to other sensors. Only the setting»output characteristic rising/falling«can be copied to a re f e rence sensor. Warning! The changed settings are copied into the EEPROM without any further acknowledgement! Press the»enter«button until one of the yellow channel LEDs (Fig. 2, Pos. 8) flashes (after approx. 3 s). Release the»enter«button. Briefly press the»up«or»down«button until the channel is shown from which you wish to copy settings. 22
23 Activating/Deactivating a channel Press the»enter«button for approx. 5 s. The controller copies all settings from this sensor channel to all other active sensor channels and then returns immediately to normal mode. Release the»enter«button. 6.4 Activating/Deactivating a channel The activation and deactivation of channels are among the programming functions of the contro l l e r. Press the»enter«button until one of the yellow channel LEDs (Fig. 2, Pos. 8) flashes (after approx. 3 s). Release the»enter«button. Briefly press the»up«or»down«button until the channel you wish to activate or deactivate is shown. The green LEDs (Fig. 2, Pos. 7) indicate the type of sensor. Briefly press the»up«or»down«button until the type of sensor connected is shown (activation) or all sensor type LEDs flash (deactivation). Briefly press the»enter«button four times. The change is copied to the EEPROM. The controller automatically returns to normal mode. Briefly press the»enter«button. 23
24 7 Technische Daten wms-4/4i II Technical Specification Operating voltage U B 20 bis 30 V d.c., reverse polarity protection, 10% voltage ribble No-load current consumption 50 ma (without sensors) Type of connection 23 srew terminals (wire cross-section max. 1,5 mm 2 ) Outputs Controls Indicators Sensors wich may be connected Sensor connections Method of measurement Resolution Reproducibility 4 x current outputs ma 3 button & 1 slider 4 yellow LED s (sensor chanel) 8 green LED s (programming) wms-25/rt/hv/m18, wms-30/rt/hv/m30 wms-101/rt/hv/m30, wms-301/rt/hv/m30 wms-601/rt/hv/m30 up to 4 sensors with 4 wires (U 0, GND, 2 x signal lines) Echo propagation time 0,36 mm ± 1 mm in scan mode, ± 3 mm in synchronous mode Temperature drift 0,17 %/ C without temperature compensation Temparature compensation by way of ultrasonic reference measurement Measurement recording S y n c h ronous of scan (multiplex) oparation selected via slider swith Responce time 85 to 220 ms, depends on sensortype Housing Plastic housing, suitable for top-hat rail mounting (DIN EN ) Operating temperature 20 C C, non-condensing Storage temperature 40 C C Class of protection IP 20 Weight 210g EMC-resistance IEC Electrostatic dischage 4 kv/8 kv IEC HF interference 10V/m IEC Fast transient 2 kv IEC HF interference 10 V (3 V) EN irradiated interference 24
25 The address microsonic GmbH Hauert 16 D Dortmund Telefon: +49 (0) 231/ Telefax: +49 (0) 231/ Internet: Subject to change without notice Errors and omissions excepted MV-DO-817 Rev.0
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