ToughSonic TS-30S Series Dual Output Teachable Ultrasonic Sensor

Transcription

1 ToughSonic TS-30S Series Dual Output Teachable Ultrasonic Sensor Installation Instructions Senix Corporation 52 Maple St., Bristol, VT USA or FAX: Web: Revision Date: April 6, by Senix Corporation

2 Product Declarations Revision History This manual applies to hardware revisions J, K Initial Release, TS-30S Rev J July 13, 2004 Powersave and switch overload indication not yet implemented (beginning S/N ) Corrected output ratings July 15, 2004 Corrected 485 and 485- identification Oct 7, 2004 Delete short range, change teach indication Nov 3, 2004 Corrected cm values in table 4 Mar 4, 2005 Add temp compensation, remove Powersave Mar 15, 2005 Replace TS-30S3 with TS-30S2 series Mar 25, 2005 Revised TS-30S2 defaults Apr 6, 2005 Related Models TSL-30Sx Series Ultrasonic level control with dual level control and alarm outputs. These sensors are packaged identically to the TS-30Sx series described in this document. ULTRA-30 Series High sensitivity models ULTRA-30-VA and ULTRA-30L-VA provide a 0-10 VDC output in a 30-mm threaded, anodized aluminum case, and are CE compliant. Page 2 of 29 April 6, 2005

3 TABLE OF CONTENTS PRODUCT DECLARATIONS...2 Revision History...2 Related Models...2 ULTRASONICS OVERVIEW...4 Introduction...4 Advantages...4 Typical Applications...4 Terminology...5 SENSOR OVERVIEW...6 Specifications...6 Features...6 Product Series...7 Part Numbers...7 Identification...7 Mechanical Details...8 Accessories...8 Orientation...8 Mounting...9 Applying Power...9 Temperature Compensation...9 Detection Area...10 Connections & Wiring...11 ADJUSTMENT...16 Sensor Rear Features...16 TEACH Button...16 Target Indicator...16 Output Status Indicators...18 Teachable Features...22 Adjustment Sequence...26 Performance...27 Precautions...27 Maintenance & Cleaning...27 IN CASE OF DIFFICULTY...28 Basic Checkout...28 Warranty...29 Repairs and Returns...29 LIST OF FIGURES Figure 1 - Range by Series...7 Figure 3 - Part Number Structure...7 Figure 4 - Mechanical Drawing...8 Figure 5 - Sensor Orientation...8 Figure 6 - Angle vs. Distance-Flat Surface Target.8 Figure 7 - Mounting...9 Figure 8 - Typical Area Coverage TS-30S1 Series10 Figure 9 - Connections (non serial data models)..11 Figure 10 - Connections, RS-232 Models...11 Figure 11 - Connections, RS-485 Models...11 Figure 12 - Voltage Output Wiring...12 Figure 13 - Current Loop Output Wiring...13 Figure 14 - Sinking Switch Output Wiring...13 Figure 15 - Sourcing Switch Output Wiring...14 Figure 16 - RS-232 & RS-485 Wiring...14 Figure 17 Default SYNC Timing...15 Figure 18 Sensor Rear View...16 Figure 19 Target Indicator Operation...17 Figure 20- Target Indicator Funcions...17 Figure 21 Output #1 and Output #2 Indicator Functions by Model Number...19 Figure 22 - Analog Output Indicator Functions...20 Figure 23 - Switch Output Indicator Functions...21 Figure 24 Serial Data Indicator Functions...22 LIST OF TABLES Table 1 - Model Numbers & Outputs 7 Table 2 - Cable Connections 11 Table 3 - Serial Data Specifications 14 Table 4 - Max Range vs. Measure Rate 23 Table 5 - Response Time vs. Measurement Rate _24 Table 6 - Pushbutton TEACH Features List 25 Page 3 of 29 April 6, 2005

4 Ultrasonics Overview Introduction Senix sensors measure the distance or presence of a target object by sending a sound wave, above the range of hearing, at the object and then measuring the time for the sound echo to return. Knowing the speed of sound, the sensor can determine the distance of the object from the transducer element. ( 1 ) U l t r a s o n i c p u l s e t r a n s m i t t e d from Advantages! Non-contact Measures through the air without touching the target object, at relatively large distances.! Object Ranging Object distance is measured rather than just the presence or proximity.! Distance Proportional Output The sensor s outputs are proportional or affected by the measured target distance.! High Resolution Precise discrimination of target position.! Unaffected by Target s Optical Characteristics The sensor s operation is not sensitive to ambient light levels, the color of the target, or target is optically transparency/reflectivity.! Sensitive Detects large and small objects. sensor ( 2 ) U l t r a s o n i c e c h o r e t u r n s from target Typical Applications Roll Diameter Measure the size of a roll to control tension or speed, or determine full/empty target. Loop Control Precisely control the position of material loops, including wires, tubes and webs. Web Break Rapidly detect a broken web in a printing press or paper machine. Dimensioning Determine the size of an object for information or to determine its volume or width. Proximity Determine the presence of objects to count or control their movement. Sort/Select Sort or select objects based on differences in their physical dimensions. Level Measurement Measure the level of liquid or solid materials in tanks or bins for inventory or batching.and many more... Page 4 of 29 April 6, 2005

5 Terminology Terms listed here are shown in italics throughout this document. Analog An electrical output type that varies in proportion to measured distance. Analog output types can be either current loop outputs or voltage outputs. Analog High Limit The maximum (highest) value of an analog output. For example, the Analog High Limit value for a 4-20 ma. current loop analog output is 20 ma. Computer configurable models allow this value to be user-entered. Analog Low Limit The minimum (lowest) value of an analog output. For example, the Analog Low Limit value for a 0-10 VDC voltage output is 0 volts. Computer configurable models allow this value to be user-entered. Analog Window A range of distances between two endpoints, within which the analog output will vary between the analog low limit and analog high limit proportional to measured distance. Current Loop Output An analog output type that drives an electrical current proportional to measured distance. Senix sensors can provide industry standard 4-20 ma. current loop outputs. Endpoint One of two end distances representing the outer limits of the analog window. Ingress Rating An enclosure rating that identifies how susceptible a product is to the entry (ingress) of external objects or liquids. Measurement Rate The repetitive rate that the sensor measures distance (see response time). Maximum Range The maximum distance at which the sensor will detect a target and report distance. Computer configurable models allow this value to be user-entered. Minimum Range The minimum distance at which the sensor will begin to detect a target and report distance. Computer configurable models allow this value to be user-entered. Operating Window The range of distances between the min range and max range values. Output Status Indicator An indicator at sensor rear that shows the status of an analog, switch or serial data output. There is a separate output status indicator for output #1 (black wire) and output #2 (white wire). RS-232 An electrical interface standard used to transfer information using serial data communications. This is a single ended interface with a specified maximum range of 50 feet (15 meters) that typically supports one device. RS-485 An electrical interface standard used to transfer information using serial data communications. This is a differential interface with a specified maximum range of 2000 feet (600 meters) that is capable of supporting multiple addressable devices. Response Time The time required for sensor outputs to respond to measurements (see measurement rate). Serial Data A method of transferring information using a sequential (serial) on/off pattern to encode the data. Two common industry standards are RS-232 and RS-485. Setpoint The measured distance at which a switch output turns ON. Sinking A switch type that sinks current from an external load to ground when turned ON. An ON sinking switch output measures a low voltage. Sourcing A switch type that sources current from the sensor to the load when turned ON. An ON sourcing switch output measures a high voltage. Switch An electrical output type that is either ON or OFF. ToughSonic switches are solid state. Target Any object or material that reflects ultrasonic energy back to the sensor thus allowing the sensor to measure its distance. Target Indicator An Indicator at sensor rear that shows the status of a detected target. Teach A Senix product feature that uses the sensor s pushbutton to tell the sensor to store a current target distance measurement into memory and automatically calibrate the output(s). Ultrasonic A sound wave of a frequency greater than 20,000 Hz, typically above the range of human hearing. Voltage Output An analog output type that drives an electrical voltage proportional to measured distance. Senix sensors provide industry standard 0-10 and 0-5 VDC outputs. Page 5 of 29 April 6, 2005

6 Sensor Overview Specifications Input Voltage Input Current Range TS-30S1 series TS-30S2 series Outputs * Measurement Rate * Response time* Resolution Repeatability VDC (15 VDC min for 0-10 VDC out) 65 ma max, plus output loads (MIN-MAX) in. ( cm) in. ( cm) Dual output, varies with model. Pushbutton teachable 40 measurements/second (default) (25 msec period) see Measurement Rate, pg msec (FAST response, default) 2 inches/second (SLOW response) see Response Time, page inches (0.086 mm) Analog outputs: 12 bits over span 0.1% target temp Temperature -40 to 70 C (-40 to 158 input voltage 24 VDC or less Humidity Connections Indicators Enclosure Ingress Rating 0-100%, heavy condensation may affect readings 6-ft. (2 m) attached cable Target Indicator (round LED) Output #1 Status (square LED) Output #2 Status (rectangle LED) 303 Stainless Steel IP68 Weight 11 oz. (312 g) Housing Size Length: in. (103 mm) Diameter: 30mm x 1.5 pitch See mechanical details page 8 Current Loop Sinking Switch Sourcing Switch 4-20 ma. sourcing maximum loop resistance: 500Ω >15VDC 250Ω 10 VDC VDC max. 150 ma. max. at input voltage RS-232, RS baud, N, 8, 1 (see pg. 14) SYNC Permits up to 32 sensors to be used in same area (see pg. 15) * Pushbutton Teachable, see page 22. Transducer Type Rugged piezoelectric Beam Pattern See page 10 Features ToughSonic sensors measure distance without contact and are designed for tough industrial environments. Key features include: Non-contact sensing as close as 1.75 inches (4.4 cm) or as far as 14-ft (4.25m) Rugged stainless housing with permanently attached interface cable Dual output. Models are available in several output combinations. User-adjustable settings for application flexibility All adjustments are teachable using a rear pushbutton LED indication of target status (In range, no target, too close) LED indication of the status of each output INTERFACE SPECIFICATIONS Voltage * 0-5 and 0-10 VDC, 10 ma. max (minimum 15 VDC input voltage for 0-10 VDC output) Page 6 of 29 April 6, 2005

7 Product Series ToughSonic sensors with 30mm threads are offered in two series. Each series has different minimum and maximum ranges of operation.. Figure 1 - Range by Series Part Numbers TS - 30S x-xxx xxx OUTPUT #2 (WHITE) V: 0-10 and 0-5 VDC SK: Sinking Switch SR: Sourcing Switch 232: RS-232 Data Out OUTPUT #1 (BLACK) I: 4-20 ma. current loop SK: Sinking Switch Output SR: Sourcing Switch Output 485: Output 1, Output 2 - RANGE 1: Long = in. ( cm) 2: Short = in. ( cm) These ToughSonic series include several model numbers. The model number identifies the output combination as shown in Table 1: Model Output #1 Output #2 (Black wire) (White wire) TS-30Sx-IV 4-20 ma. current 0-10 VDC loop (1) TS-30Sx-ISK 4-20 ma. current sinking loop switch TS-30Sx-ISR 4-20 ma. current sourcing loop switch TS-30Sx-SKV sinking 0-10 VDC switch (1) TS-30Sx-SRV sourcing 0-10 VDC switch (1) TS-30Sx-SKSK sinking sinking switch switch TS-30Sx-SRSR sourcing sourcing switch switch TS-30Sx-SKSR sinking sourcing switch switch TS-30Sx-SK232 sinking GRAY Wire: switch RS-232 Out TS-30Sx-SR232 sourcing GRAY Wire: switch RS-232 Out TS-30Sx-485 YELLOW Wire: GRAY Wire: RS-485 RS-485- Notes: (1) A 0-10 VDC output can be changed to 0-5 VDC using TEACH 30 (see Table 6 on page 25). Table 1 - Model Numbers & Outputs The TS-30S is available in two ranges, as identified by the x in Table 1. Replace x with as follows: x = 1 for TS-30S1 series x = 2 for TS-30S2 series Identification The ToughSonic model number and serial number are printed on the label on the side of the housing. HOUSING 30S: 30mm threaded stainless steel PRODUCT SERIES TS: ToughSonic(TM) Ultrasonic Sensor Figure 2 - Part Number Structure Page 7 of 29 April 6, 2005

8 Mechanical Details Orientation Orient the sensor perpendicular to the target object for best results as shown in Figure 4. DIRECTION OF MEASUREMENT Figure 4 - Sensor Orientation Figure 3 - Mechanical Drawing The transducer is recessed into the case in the TS- 30S2 series. For all series, the distance is measured from the transducer end of the housing, not from the transducer face. Accessories The following types of accessories are available. Mounting Brackets Several types are available, providing either fixed or adjustable sensor positions. Stainless Nuts The sensor is shipped with two plastic 30mm mounting nuts. Stainless nuts are available. Digital Indicators Digital indicators are available to display distance or level measurements. Ultrasound energy must reflect back to the sensor or the sensor will not detect the target. Curved or spherical objects can make good targets because they generally reflect a portion of the energy back to the sensor. However, a flat surface can be detected at a greater distance than a curved surface. Make sure that other unintended targets are not visible to the sensor or false readings may result. Typical measurement angles of deviation from perpendicular relative to a large flat surface are shown in Figure 5. TS-30S1 Series TS-30S2 Series Feet meters Angle (deg) Inche s mm Angle (deg) Figure 5 - Angle vs. Distance-Flat Surface Target Page 8 of 29 April 6, 2005

9 Mounting The sensor mounts through a hole approximately 1.2 in. (30.5 mm) in diameter as shown in Figure 6.This hole must be available in a bracket or component provided by the user. Position the sensor in the hole and fasten the sensor to the plate with the two nuts provided. The sensor position can be altered a couple of inches depending on where the nuts are placed on the sensor body. Keep the sensor face a distance of at least the minimum range from the closest target position (see Range MIN specification on page 6). between the front of the transducer and the liquid surface. Temperature compensation is less important if under normal use the temperature environment surrounding the sensor remains fairly constant. If temperature compensation is used outdoors the temperature sensor should be protected from the sun or heating of the sensor will cause measurement errors. Figure 6 - Mounting Applying Power After the sensor is wired as described in Connections & Wiring on page 11, it is activated by applying power. Outputs will then operate as described on page 12 and the rear indicators will operate as described on pages 16 and 18. Temperature Compensation At room temperature, a change of 10 degrees will result in approximately 1% change in the speed of sound and therefore the same change in the distance between the sensor and each Setpoint (without temperature compensation). If this is an issue in your system you may want to consider turning temperature compensation ON using TEACH. ToughSonic sensors have a temperature sensor at the rear that can be used for temperature compensation. Temperature compensation can be turned ON and OFF using TEACH. The factory default is OFF. For best results the temperature at the rear of the sensor should reflect the temperature of the air Page 9 of 29 April 6, 2005

10 Detection Area The distance at which a target can be detected depends on the size and shape of the object. The approximate sensing areas for some common targets Figure 7 - Typical Area Coverage TS-30S1 Series are shown in Figure 7. The sensitivity to large flat surfaces is shown in Figure Target Area Coverage for Typical Targets Inches Off Axis /8" Diameter Cylinder Flat Surface, measured by rotating sensor Inches /2" Floppy Disk measured by rotating sensor 540 Page 10 of 29 April 6, 2005

11 Connections & Wiring SHIELD Output #1 (Black) Output #2 (White) GND (Blue) Gray DC (Brn) SYNC - To Yellow wire of SLAVE sensors (assumes above sensor is a MASTER) * 15 VDC min for 0-10 VDC out Input VDC* Power Supply - Input 2 User Equipment Input - Single point ground Figure 8 - Connections (non serial data models) Output #2 (Gray) Output #1 (Black) GND (Blue) SHIELD DC (Brn) RS-232 Out Switch (sourcing or sinking) VDC Power Supply Figure 9 - Connections, RS-232 Models Output #1 (Yellow) Output #2 (Gray) GND (Blue) SHIELD DC (Brn) - RS-485 Out RS-485- Out VDC Power Supply Figure 10 - Connections, RS-485 Models - RS-232 In Input 1 User Equipment Input - Single point ground RS-485 in RS-485- in User Equipment Input - Single point ground The above figures show how the different colors of the 6-wire cable (plus shield) are used for the different models in typical user connections. Cable All sensor connections are made through the 2m cable at the sensor rear. This cable contains 6 wires. The BLACK, WHITE, GRAY and YELLOW wires contain outputs that vary by part number (see Table 1). Wire colors meet EU standards and are shown in Table 2. Wire Color BROWN BLUE GRAY YELLOW DC IN (power) GND Signal SYNC MASTER (1) RS-232 out (Out #2, RS-232 Models) RS-485- (Out #2, RS-485 model) SYNC SLAVE (1) RS-485 (Out #1-RS-485 model) BLACK Output #1 (see Table 1) WHITE Output #2 (see Table 1) Bare wire Cable Shield (stranded wire) Notes: (1) Leave unconnected if not used. SYNC is not applicable on models with serial data outputs Ground (blue wire) Table 2 - Cable Connections The ground wire is common to both the power supply and the output circuits and used as described below. Cable Shield (bare wire) The cable shield is not terminated inside the sensor. This wire should be terminated to equipment ground near the user equipment, preferably to a single point ground for all equipment. Power Input (brown wire) Connect a DC power supply to the DC (Brown) and GND (Blue) wires shown in Table 2. These colors conform to EU standards. The power supply must be between VDC if using an analog output, or VDC for all other interfaces. Reversing the power connections will not damage the sensor. When power is applied, the rear LED target indicator will light and the sensor measures as described in Applying Power on page 9. Page 11 of 29 April 6, 2005

12 OUTPUTS (Black and White wires) The sensor has two outputs available on the BLACK and WHITE wires. The type of output connected to each wire depends on the sensor part number as shown in Table 1 on page 7. The outputs are also identified on the sensor s rear label. There are several types of output provided in various combinations: Analog voltage output, 0 10 VDC (or 0-5 VDC using Teach feature 30) Analog current loop output, 4-20 ma Voltage Output DC Sensor DC (Brown) 0-10 VDC (White) GND (Blue) Cable Shield - - Power Supply (24 VDC typical) User Equipment (Voltage Input) GND Single point ground optional (recommended) Sinking switch (transistor) Sourcing switch (transistor) Each of these output types is described in following sections. Refer to the Specifications on page 6 for information on the sensor outputs. OUTPUTS (Yellow and Gray wires) The YELLOW and GRAY are used for data communications and SYNC functions. These functions are mutually exclusive. Data communications functions are described on page 14. Optional SYNC functions as described on page 15. The following models have serial data outputs on the YELLOW and/or GRAY wires: Serial Data RS-232 (output only) Uses GRAY for data output Serial Data RS-485 (output only) Uses both GRAY and YELLOW for data outputs Each of these output types is described in following sections. Refer to the Specifications on page 6 for information on the sensor outputs. Figure 11 - Voltage Output Wiring The Voltage Output is a 0 to 10 volt DC signal proportional to the measured distance between the endpoints set by the user. The voltage range can be changed to 0-5 VDC using the TEACH button. The polarity of the output is reversible. If the sensor model has this output (see Table 1 on page 7) it is connected to the WHITE wire and measured relative to GND (BLUE wire). The 0 and 10 volt endpoints can be adjusted anywhere in the sensor s range using the TEACH button. The TEACH button adjustments that affect this output are listed in Table 6 on page 25. The sensor will use the default configuration endpoints unless changed by the user. Refer to the Adjustment Sequence on page 26 for instructions on changing the endpoints. NOTE: Sensor models TS-30Sx-IV have both voltage and current loop outputs. The TEACH button distance adjustments affect both outputs simultaneously, i.e., they are not independently adjustable. The analog inputs of the User Equipment are either differential (both and terminals) or single ended ( terminal and GND). A single ended input is relative to the User Equipment s ground. Page 12 of 29 April 6, 2005

13 Current Loop Output Sinking Switch Output Sensor DC (Brown) 4-20 ma. (Black) Direction of current flow GND (Blue) Cable Shield - - Power Supply (24 VDC typical) User Equipment (Current Loop Input) Maximum loop resistance 24 VDC sensor input voltage may be GND if single ended Single point ground optional (recommended) Typical PLC Input (DC) Sensor DC (Brown) Direction of current flow GND (Blue) Cable Shield - Gnd Power Supply (24 VDC typical) Pullup User Equipment (Discrete input) Single point ground optional (recommended) Figure 12 - Current Loop Output Wiring The Current Loop output is a 4 to 20 ma. current sourcing signal proportional to the measured distance between the endpoints set by the user. The polarity of the output is reversible. If the sensor model has this output (see Table 1 on page 7) it is connected to the BLACK wire. Current flows out of the sensor, through the user equipment and back to the sensor GND (BLUE wire). The 4 and 20 ma. endpoints can be adjusted anywhere in the sensor s range using the TEACH button. The TEACH button adjustments that affect this output are listed in Table 6 on page 25. The sensor will use the default configuration endpoints unless changed by the user. Refer to the Adjustment Sequence on page 26 for instructions on changing the endpoints. NOTE: Sensor models TS-30Sx-IV have both voltage and current loop outputs. The TEACH button distance adjustments affect both outputs simultaneously, they are not independently adjustable. The analog inputs of User Equipment are either differential (both and terminals) or single ended ( and GND terminals). A single ended input is relative to the User Equipment s ground. Other Typical Uses Sensor Switch ON energizes relay coil - when switch turns off diode D1 protects transistor from inductive kick D1 K1 Sensor R1 LED Switch ON turns on LED. R1 limits LED current Figure 13 - Sinking Switch Output Wiring The sinking switch is an open collector transistor (solid state switch) that sinks current from an external load to GND when ON as shown in Figure 13. Some sensor models have one and some have two of these output(s) (see Table 1 on page 7), and the output(s) are connected to either or both the BLACK and/or WHITE wires. The switching distance (setpoint) can be adjusted anywhere in the sensor s range using the TEACH button, and the polarity is reversible about the setpoint. If the sensor model has two switches each has an independently adjustable setpoint and Polarity. Adjustments that affect this output are listed in Table 6 on page 25. The sensor will use factory default setpoints unless changed by the user. Refer to the Adjustment Sequence on page 26 for instructions on changing the setpoints. Note: If the Response Time (page 23) filter is set to SLOW there may be a time delay for the switch state to change. If the sensor does not detect a target within its range the switch(es) will turn OFF either immediately or after 1 second depending on TEACH Feature 20 (see Table 6). Page 13 of 29 April 6, 2005

14 Sourcing Switch Output Typical PLC Input (DC) Sensor DC (Brown) Direction of current flow GND (Blue) Cable Shield Other Typical Uses (power & GND not shown) Sensor D1 K1 - Gnd Sensor Power Supply (24 VDC typical) User Equipment (Discrete input) Single point ground optional (recommended) R1 LED RS-232 and RS-485 Outputs RS-232 Wiring Sensor RS-485 Wiring DC (Brown) (Gray) GND (Blue) User Equipment (RS-232 data Input) DB9* DB25* RX 2 3 GND 5 Single point ground Cable Shield optional (recommended) * Typical personal computer connections for 9 and 25-pin serial COM connectors - - Power Supply (24 VDC typical) 7 Power Supply (24 VDC typical) Switch ON energizes relay coil K1 - when switch turns off diode D1 protects transistor from inductive kick Switch ON turns on LED. R1 limits LED current Sensor DC (Brown) RS-485 (Yellow) RS-485- (Gray) - User Equipment (RS-485 data Input) Figure 14 - Sourcing Switch Output Wiring The sourcing switch is solid state and sources current to an external load to turn that load ON or OFF as shown in Figure 14. Some sensor models have one and some have two of these output(s) (see Table 1), and the output(s) are connected to either or both the BLACK and/or WHITE wires. The switching distance (setpoint) can be adjusted anywhere in the sensor s range using the TEACH button, and the polarity is reversible about the setpoint. If the sensor model has two switches each has independently adjustable setpoint and Polarity. Adjustments that affect this output are listed in Table 6 on page 25. The sensor will use the factory default setpoints unless changed by the user. Refer to the Adjustment Sequence on page 26 for instructions on changing the setpoints. Note: If the Response Time (page 23) filter is set to SLOW there may be a time delay for the switch state to change. If the sensor does not detect a target within its range the switch(es) will turn OFF either immediately or after 1 second depending on TEACH Feature 20 (see Table 6). GND (Blue) Cable Shield GND Single point ground optional (recommended) Figure 15 - RS-232 & RS-485 Wiring The RS-232 and RS-485 output are a serial digital data stream transmitted every 50 msec. (faster using Teach Features 25-27). Wiring is shown in Figure 15. Sensor models with these outputs are identified in Table 1 on page 7. Only the SLOW/FAST response time TEACH feature (page 23) affects the data in these outputs. These outputs are transmit-only. Specifications are shown in Table 3. Format Resolution Output Stream Distance Calculation Zero s output ASCII, 9600 baud, 8 data bits, 1 stop bit, no parity inches/count (nominal speed of sound 1128 ft./sec) 5-ASCII byte Count Value between 0 and 65535, carriage return terminated Multiply count value of Output Stream by Resolution Theoretical: distance of sensor face Actual: no target detected in range Table 3 - Serial Data Specifications The Output Stream transmitted by the sensor is a count value proportional to measured distance. The count value, multiplied by the Resolution, results in Page 14 of 29 April 6, 2005

15 measured distance. For example, the equivalent distance for a count value of is: * = inches User equipment must be programmed to convert the ASCII output stream to a numeric value, then either use the count value directly or calculate the distance units by multiplying the count by a distance resolution factor that results in the desired units. SYNC Connection The SYNC connection allows two or more sensors to operate in near proximity without interference. The SYNC feature is not applicable for models with serial data outputs. For single sensor applications, leave the SYNC wires unconnected. If two or more sensors are in near proximity the ultrasonic output from one sensor can interfere with another sensor s measurements either by direct or reflected ultrasonic cross talk. The symptom of sensor interference is an output (analog or switch) jumping intermittently but somewhat repetitively to a value or state representing a target closer to the sensor than the actual target. This symptom may disappear or be less severe when the output response time (page 23) filter is set to SLOW. If interference is suspected, turn off all but one sensor to determine if the output stabilizes. To use the SYNC feature, select ONE sensor in a group of 2 or more to be the MASTER using TEACH feature 12. Then, connect the Gray wire of the MASTER sensor to the Yellow wire(s) of all other (SLAVE) sensors. This will cause the master to measure at Phase 1 and all slaves to measure at Phase 2 (see Figure 16). The times shown in Figure 16 will be correspondingly faster for higher measurement rates (see Measurement Rate on 23). There are two possible SLAVE settings A and B. The factory default is SLAVE A, which measures at time φ2. The MASTER sensor will measure at time φ1, which is 25 msec offset from the SLAVE-A. A sensor is set to SLAVE-A (1) at the factory, (2) using TEACH feature 17 to establish a factory configuration, or (3) using TEACH feature 13. SLAVES can also be set to operate on φ1 by configuring them as SLAVE-B using TEACH feature 14. When set to SLAVE-B they will measure at the same time as the MASTER. When a sensor is configured as a MASTER its measurement rate is cut in half from 40 measurements/ second to 20 measurements/second to allow 25 msec between SYNC phases φ1 and φ2. Each SLAVE sensor will automatically detect an active SYNC input. When an active SYNC input is detected the slave measurement rate will synchronize to the master at 20 measurements per second. If the SYNC input is not active the SLAVE sensor will begin measuring asynchronously at 40 measurements/ second. These periods are affected proportionally if faster measurement rates are selected using TEACH feature 25, 26 or 27. A synchronized slave sensor will revert to autonomous operation after 500 msec if the MASTER signal is lost. Under this circumstance (SYNC is detected then lost) the slave will change the target indicator to alternately blink Red and as a SYNC LOST warning. Flashing will end when SYNC is reestablished, the TEACH button is pressed or sensor power is cycled off then on. In a two-sensor installation where interference is a factor, set one sensor to MASTER. The other will operate as slave A as per the default configuration. Figure 16 Default SYNC Timing Page 15 of 29 April 6, 2005

16 Adjustment Sensor Rear Features Target Indicator The target indicator is a 2-color LED that serves the following purposes: Power Status Target Status Unlocked Status Sync Lost Warning Figure 17 Sensor Rear View The rear sensor controls are shown in Figure 17. There are four control features available: The TEACH button is used to make sensor adjustments. The target indicator (round) shows the target status. It also indicates an Unlocked condition during adjustment, and serves as the power-on indicator, and blinks RED during TEACH operations. The output #1 status indicator (square) shows status of the output connected to the sensor s black wire. The type of output and indicator function varies with sensor model. Power Status When sensor power is applied the target indicator will light and the sensor will begin measuring. The target indicator will be RED or GREEN, and may be flashing at a slow or fast rate depending on the function being indicated (see Figure 18 and Figure 19). Unlocked Status The sensor must be unlocked to make adjustments. When unlocked the target indicator will continue to indicate target status except the indicated conditions will be slowly alternating on and off. Sync Lost Warning If the SYNC feature is used (see SYNC Connection page 15) and a slave sensor acquires then looses the master sensor s SYNC signal, the slave will revert to autonomous operation and slowly alternate between RED and GREEN until SYNC is restored. The output #2 status indicator (rectangle) shows status of the output connected to the sensor s white wire or gray wire (serial data models only). The type of output and indicator function varies with sensor model. TEACH Button The TEACH button is used to make all sensor adjustments. When this button is pressed and held both the Target indicator will blink RED in response. Adjustments occur by releasing the pushbutton after the indicator blinks a specific number of times. Button usage is described in Teachable Features on page 22. Page 16 of 29 April 6, 2005

17 Target Status The target indicator displays target status as follows: GREEN is a normal indication, indicating a target is detected within the sensor s range SOLID RED indicates no target is detected within the sensor s range FAST FLASH RED indicates a target closer than the sensor s minimum range. As the target moves closer to the sensor face detection may become less reliable. Target No Target Too Close Target No Target Too Close Target Indicator (All Models) Round Dual-Color Indicator Red Time Normal Red Unlocked (for Adjustment) SYNC Lost Red Blinks Red Alternating Groups of Red Blinks All Red Alternating Red and This indication will only appear at a SLAVE sensor that has engaged then lost a SYNC input. Figure 18 Target Indicator Operation MIN range Sensor Body 0 sensor operating window (see series specifications) MAX range DISTANCE TARGET POSITIONS NORMAL: R R R R fast flash RED Solid green when any target in sensor's operating window Solid Red solid RED if no target in Range UNLOCKED R R Off Off Off Red Off alternating flash groups alternating green when any target in range alternating Red SYNC LOST Red Red Red Red alternating Red/ (unrelated to target distance or status) Figure 19- Target Indicator Funcions Page 17 of 29 April 6, 2005

18 Output Status Indicators Each sensor model has two outputs, identified as Output #1 and Output #2. Each output has a green output status indicator. The electrical outputs types differ by model number, and the indicator function therefore varies depending on the type of output. Figure 20 summarizes the indicator combinations for all models. Identification Output #1 Status Indicator Square green indicator ( ) Associated with output connected to the BLACK wire Indicates either switch, analog status depending on sensor model Output #2 Status Indicator Rectangular green indicator ( ) Associated with output connected to the WHITE wire Indicates either switch, analog status depending on sensor model For serial data models this indicator flashes each time data is transmitted from the sensor Switch Status Output #1 and/or Output #2 may be a solid state switch for some models (see Figure 20). The indicator will operate as follows for a switch: connected output is pulled to ground (output is a lower voltage). Analog Status Output #1 and/or Output #2 may be an analog signal (voltage or current loop) for some models (see Figure 20). The indicator operates as follows: Indicator ON if analog value is anything other than the minimum or maximum. Indicator OFF if analog value is at the minimum (0 VDC or 4 ma.) Indicator blinks ON-OFF if analog value is at the maximum (5/10 VDC or 20 ma) In a typical installation the analog output is operating within a user-calibrated range and the normal indication is therefore a continuously ON indicator. An OFF or blinking indicator would then indicate a problem because the sensor is detecting a target outside of the expected (calibrated) distance range. Data Status For models with data outputs (RS-232 or RS-485) the Output #2 Indicator will flicker each time data is transmitted. TEACH Indication When using the TEACH features to make sensor adjustments (see page 26) the Target Status Indicator will blink RED to provide operator feedback while the TEACH button is pressed. The user must count these flashes, then release the TEACH button after a specific number of flashes to engage a particular TEACH feature. Indicator ON if switch is ON Indicator OFF if switch is OFF Indicator blinks if switch is overloaded. An overloaded switch goes into a safe shutdown mode when the switch is shorted or over temperature. Switch outputs may be either sinking ( SK ) or sourcing ( SR ) but the indication is the same. A switch is considered ON when it is conducting current. A sourcing switch is therefore ON when the output is driven to the supply voltage (output is a higher voltage). When a sinking switch is ON the Page 18 of 29 April 6, 2005

19 Output #1 (Black Wire) Square Indicator Models: TS-30S1-IV, TS-30S3-IV Output #2 (White Wire) Rectangular Indicator Output: Current Loop Output: Voltage At low value Off At low value Off In Range In Range At Hi Value At Hi Value Models: TS-30S1-SKV, TS-30S1-SRV, TS-30S3-SKV, TS-30S3-SRV Output: (SKV) Sinking Switch, (SRV) Sourcing Switch Output: Voltage OFF Off At low value Off ON In Range Overload At Hi Value Models: TS-30S1-ISK, TS-30S1-ISR, TS-30S3-ISK, TS-30S3-ISR Output: Current Loop Output: (ISK) Sourcing Switch, (ISR) Sinking Switch At low value Off OFF Off In Range ON At Hi Value Overload Models: TS-30S1-SKSK, TS-30S1-SKSR, TS-30S1-SRSR, TS-30S3-SKSK, TS-30S3-SKSR, TS-30S3-SRSR Output: (SKSK, SKSR) Sinking Swith, (SRSR) Sourcing Switch Output: (SKSK) Sinking Swith, (SKSR,SRSR) Sourcing Switch OFF ON Overload Off OFF ON Overload Off OFF ON Overload Models: TS-30S1-SK232, TS-30S1-SR232, TS-30S3-SK232, TS-30S3-SR232 Output: (SK232) Sinking Switch, Output: RS-232 TX (SR232) Sourcing Switch Tx Off Flickers each time data is transmitted Models: TS-30S1-485, TS-30S3-485 NOTE: This output is on the GRAY wire Output: RS-485 Output: RS Tx Indicator Not Used Flickers each time data is transmitted NOTE: This output is on the YELLOW wire NOTE: This output is on the GRAY wire Figure 20 Output #1 and Output #2 Indicator Functions by Model Number Page 19 of 29 April 6, 2005

20 Analog Output Status (0-10 VDC and/or 4-20 ma current loop) In normal operation the target indicator operates as shown in Figure 21 for sensors with an analog output. During unlocked or SYNC lost operation the target indicator operates as shown in Figure 18 and Figure 19. Some models with analog outputs also have switch outputs. Switch output indication is described on page 21. Table 1 on page 7 provides a complete list of all models and their outputs. Target Indicator R fast flash RED R R R GREEN when any target in sensor's operating range Solid solid RED if no target in Range Solid Red MIN range 0 Sensor Body sensor operating window (see series specifications) MAX range endpoint endpoint analog window (endpoints: TEACH 4 & 5) TARGET POSITIONS DISTANCE Output Status Indicator When Increasing Slope When Decreasing Slope G Off = Low Value (0 VDC / 4 ma) = In Span G G G Hold Prior Condition LOW = Off HI = Fast flash G G G G G G = In Span Off = Low Value Hold Prior Condition HI = Fast flash LOW = Off Current Loop output indicated on output status indicator #1, Voltage output indicated on output status indicator #2 Figure 21 - Analog Output Indicator Functions There are two output status indicators. Sensor models with a current loop output have the current loop output status indicated on output status indicator #1 (square green ). Sensor models with a voltage output the voltage output status indicated on output status indicator #2 (rectangular green ). For models with both current loop and voltage outputs (TS-30Sx-IV) both indicators operate simultaneously and identically since they are not independently adjustable. Please note the following about analog status indication: Both status indicators are GREEN. An ON status indicator is a normal analog status and indicates that the target is between the two endpoints of the analog window. The adjustable endpoints are set using TEACH Features 4 and 5 (see Table 6 on page 25). The two output status indicator examples shown above show an increasing analog slope (top) and decreasing analog slope (bottom). An increasing slope means the output value increases proportional to the measured distance and vice versa. A FAST FLASHING output status indicator means that the analog output is at the highest possible value (10 VDC or 20 ma.). That value will occur at the distance equal to the high analog endpoint and all distances extending away from the analog window (whether closer to or farther from the sensor). An OFF status indicator means that the analog output is at the lowest possible value (0 VDC or 4 ma.). That value will occur at the distance equal to the low output analog endpoint and at distances extending away from the analog window (whether closer to or farther from the sensor). If no target is detected (target indicator is red) the analog output will retain the value associated with the last measured target distance and the output status indicator will continue to display that condition. Regardless of the output conditions, both output status indicators will SLOW FLASH to serve as user feedback when the TEACH button is pressed and held. Page 20 of 29 April 6, 2005

21 Switch Output Status (Sinking and/or sourcing) and RS-232 In normal operation the target indicator operates as shown in Figure 22 for sensors with a switch output. Switch outputs may be either sinking or sourcing but the indication is the same. Sensor models with switch outputs may have either 1 or 2 switches. Electrically, switch #1 is connected to the black wire and switch #2 to the white wire. During unlocked or SYNC lost operation the target indicator operates as shown in Figure 18 and Figure 19. Some models with switch outputs also have analog or serial data outputs. Analog output indication is described on page 20. Serial data output indication is described on page 22. Table 1 on page 7 provides a complete list of all models and their outputs. Target Indicator R fast flash RED R R R GREEN when any target in sensor's operating range Solid solid RED if no target in Range Solid Red MIN range Sensor Body 0 sensor operating range (see series specifications) MAX range polarity settings SW1=TEACH 8 SW2=TEACH 10 setpoint distance SW1=TEACH 7 SW2=TEACH 9 TARGET POSITIONS DISTANCE Output #1 or #2 Status Indicator Conditions ON Closer ON Farther = Switch ON (active) Off = Switch OFF OFF or Delayed OFF (see TEACH 20) Off = Switch OFF = Switch ON (active) OFF or Delayed OFF (see TEACH 20) Fault G G G G G G G G G G G G G G G G G G G G continuous flashing independent of target measurement, switch is OFF Figure 22 - Switch Output Indicator Functions There are two output status indicators. Sensor models with one or two switch outputs may have a switch on either or both of Output #1 and Output #2. The switch #1output status is indicated on output status indicator #1 (square green ) and switch #2 status indicated on output status indicator #2 (rectangular green ). Please note the following: An indicator will light green when the associated switch is ON. An ON switch means is it conducting current, and an OFF switch not. A sinking switch output that is ON will have an output value near ground (0 volts). A sourcing switch output that is ON will have an output value near the power supply voltage. The three output status indicator examples shown above demonstrate a switch that is ON at distances closer than the setpoint (ON closer), farther than the setpoint (ON Farther) and a FAULT condition. Teach feature 8 is used to set the distance that switch #1 changes state, and TEACH feature 9 to reverse the state (ON closer vs. ON farther). Teach features 10 and 11 perform the same respective functions for switch #2 (see Table 6 on page 25). A FAST FLASHING output status indicator means the switch is in an overload or over temperature condition and is automatically turned OFF for protection. Normal operation will be restored automatically when the overload or over temperature condition is reversed. If no target is detected (target indicator is red) a switch output will turn OFF either immediately (or after 1 second if TEACH feature 20 is used to enable the OFF delay). Page 21 of 29 April 6, 2005

22 Regardless of the output conditions, both output status indicators will SLOW FLASH to serve as user feedback when the TEACH button is pressed and held. Serial Data Output Status For sensor models with RS-232 or RS-485 serial data outputs the Output #2 status indicator display indicates data transmission from the sensor. The indication is independent of the measured distance. Some models with data outputs also have switch outputs. Switch output indication is described on page21. Table 1 on page 7 provides a complete list of all models and their outputs. Regardless of the output conditions, both output status indicators will SLOW FLASH to serve as user feedback when the TEACH button is pressed and held. Target Indicator R fast flash RED R R R GREEN when any target in sensor's operating range Solid solid RED if no target in Range Solid Red MIN range Sensor Body 0 sensor operating window (see series specifications) MAX range DISTANCE TARGET POSITIONS Output #2 Status Indicator Flicker on TX unrelated to distance - LED flickers each time data is transmitted Figure 23 Serial Data Indicator Functions Teachable Features Many sensor features can be adjusted using the rear TEACH button and Target Status Indicator. Refer to the Adjustment Sequence on page 26 for instructions on setting these features. They are called teachable because the sensor stores actual target measurements as analog endpoints and switch setpoints. A list of available Teach features is included in Table 6 on page 25, and the recommended adjustment sequence is described in Adjustment Sequence on page 26. Unlock and Lock The locking feature is provided to prevent accidental changes to the sensor s Teach feature settings. The sensor is initially locked and must be unlocked using TEACH Feature 3 before any of the following adjustments can be made. When unlocked the target status indicator continues to operate normally except it flashes on and off slowly to indicate the unlocked condition (see Figure 18). An unlocked sensor will re-lock: When TEACH Feature 3 is used again to perform a manual re-lock Automatically 15 minutes after the last use of the TEACH button. Voltage Range The default range for the voltage output is 0-10 VDC. The voltage range can be toggled between 0-10 VDC and 0-5 VDC using TEACH Feature 30. Voltage and/or Current Span The voltage and current outputs can be set to operate over a user-determined distances (span) by setting the endpoints. In a sensor model with voltage (0-10 VDC) and/or current loop (4-20 ma) outputs, these signals will vary proportionally with the target distance between any 2 distances in the sensor s Range. These distance settings are called endpoints. Page 22 of 29 April 6, 2005

23 The distance of the low (0VDC and 4 ma.) endpoint is adjusted using TEACH Feature 4. The distance of the high (10VDC and 20 ma.) endpoint is adjusted using TEACH Feature 5. The endpoints can be in any distance order, allowing an increasing or decreasing output slope. Adjustment is made easy by pointing the sensor at the actual target then using the TEACH button to memorize that reading. The factory defaults are 0VDC/4 ma. at 10 in. (254 mm) and 10VDC/20 ma. at 40 in. (1016 mm), and can always be reestablished using TEACH Feature 17. Target indicator functions for the analog outputs are shown in Figure 21 on page 20. Switch Setpoint & Polarity If the sensor model has one or two switch outputs these can be set to turn ON or OFF at specific target distances from the sensor. These distance settings are called setpoints and must be within the sensor s range. The setpoint distances are established using TEACH Feature 7 for a switch on Output #1 (BLACK wire) and TEACH Feature 9 for a switch on Output #2 (WHITE wire). The output status indicator functions for the switch outputs are shown in Figure 22 on page 21. Switch output #1 is on the BLACK wire and switch #2 on the WHITE wire. The polarity of a switch on Output #1 can be changed between ON Closer than the setpoint or On Farther than the setpoint using TEACH Feature 8. Output #2 uses TEACH Feature 10. Increasing the measurement rate limits the maximum range of the sensor. The time required for an echo to return from a remote target is determined by the speed of sound. Since sound travels at about 1 msec per foot (3.3 msec/meter), a target at 5 feet (1.5 m) results in an echo delay of 10 msec (the sound has to travel out then back before the echo is detected). As the measurement rate is increased the sensor therefore restricts the maximum range as follows: Measure Rate (meas./sec) Maximum Range inches (cm) 500 msec 168 (427) 40 (Default) 168 (427) (244) (152) (76) Table 4 - Max Range vs. Measure Rate When operating at higher measurement rates care must be taken to prevent detection of secondary echoes. The ultrasonic wave can bounce back and forth between two surfaces, e.g., the sensor surface or mounting brackets and the target. This can cause the sensor to detect a secondary echo from a prior measurement cycle as the primary echo of the next measurement cycle, resulting in an unstable output. The factory default is ON Closer than 12 in (305 mm) for a switch on Output #1 (BLACK wire) and ON Farther than 24 in. (610 mm) for a switch on Output #2 (WHITE wire). Reestablish defaults using Teach Feature 17. If the sensor does not detect a target within its range the switch(es) will turn OFF either immediately or after 1 second depending on TEACH Feature 20. Measurement Rate The Measurement Rate is how often the sensor measures the target distance. Most applications do not require changing the Measurement rate. The factory default rate is 40 measurements per second (25 msec interval). In applications where targets are moving quickly the rate can be increased (interval decreased) using TEACH Features 25, 26 and 27. A special slow measurement rate of 1 measurement per second is available using TEACH feature 28. The rate can be restored to 40 per second using TEACH Feature 24 or 17. Page 23 of 29 April 6, 2005