APG IRU-3000 User Manual

PRODUCTS

AUTOMATION

Operator’s Manual

GROUP, INC.

IRU-2xx4/3xx4

Series

Rev. A2, 11/08

Doc. 9002673

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • E-mail: [e-mail]

Automation Products Group, Inc.

IRU-2xx4/3xx4 Rev. A2, 11/08

Table of Contents

Warranty ............................................................................................................... 3

Understanding Ultrasonics ................................................................................... 4

Description ........................................................................................................... 5

Specifications ........................................................................................................ 5

Setup & Operation ................................................................................................ 6

RS-485 Communications Data ............................................................................... 6

Command Protocol ................................................................................................ 7

Command Structure ............................................................................................... 7

Memory ................................................................................................................. 7

Command List ....................................................................................................... 8

Parameters ............................................................................................................. 9

Distance Sensor .................................................................................................... 9

Sensor Number ................................................................................................... 10

Bank Number ...................................................................................................... 10

Blanking .............................................................................................................. 11

Pulses .................................................................................................................. 12

Sensitivity ........................................................................................................... 13

Calibration ........................................................................................................... 14

Temperature Compensation ................................................................................ 15

Average ............................................................................................................... 16

Out of Range Span .............................................................................................. 17

Out of Range Count ............................................................................................ 18

Sample rate .......................................................................................................... 19

Trip Point Settings .............................................................................................. 20

Trip Types ........................................................................................................... 22

Continuous Transmit .......................................................................................... 23

Start Transmit Sensor .......................................................................................... 23

Stop Transmit Sensor .......................................................................................... 24

Start Transmit Bank ............................................................................................. 24

Stop Transmit Bank ............................................................................................. 24

Reset Parameters ................................................................................................. 25

Mounting ............................................................................................................ 25

Housings ............................................................................................................ 26

Automation Products Group, Inc.

2

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A2, 11/08 IRU-2xx4/3xx4

• Warranty and Warranty Restrictions

APG warrants its products to be free from defects of material and workmanship
and will, without charge, replace or repair any equipment found defective upon
inspection at its factory, provided the equipment has been returned,
transportation prepaid, within 18 months from date of shipment from factory.

THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER
WARRANTIES NOT EXPRESSLY SET FORTH HEREIN, WHETHER
EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE
INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

No representation or warranty, express or implied, made by any sales
representative, distributor, or other agent or representative of APG which is not
specifically set forth herein shall be binding upon APG. APG shall not be liable
for any incidental or consequential damages, losses or expenses directly or
indirectly arising from the sale, handling, improper application or use of the
goods or from any other cause relating thereto and APG’s liability hereunder, in
any case, is expressly limited to the repair or replacement (at APG’s option) of
goods.

Warranty is specifically at the factory. Any on site service will be provided at
the sole expense of the Purchaser at standard field service rates.

All associated equipment must be protected by properly rated electronic/
electrical protection devices. APG shall not be liable for any damage due to
improper engineering or installation by the purchaser or third parties. Proper
installation, operation and maintenance of the product becomes the
responsibility of the user upon receipt of the product.

Returns and allowances must be authorized by APG in advance. APG will
assign a Return Material Authorization (RMA) number which must appear on
all related papers and the outside of the shipping carton. All returns are subject
to the final review by APG. Returns are subject to restocking charges as
determined by APG’s “Credit Return Policy”.

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

3

IRU-2xx4/3xx4 Rev. A2, 11/08

UNDERSTANDING ULTRASONICS

Ultrasonic sensors measure distance by using a transducer to send out ultra­sonic bursts. Each burst contains a series of pulsed sound waves. The ultra­sonic burst emits in the shape of a cone, reflects off the detected target, and is
received by the transducer. The time required for this burst to travel to and from
the target is measured and converted into a distance measurement by the sensor.

Ultrasonic sensing is affected by several factors including the target’s surface,
size, angle and the distance from the sensor. Environmental conditions such as
temperature, humidity, gases, and pressure may also affect the measurement.
APG sensors automatically compensate for most of these varied environments.
The following considerations will help ensure the best possible sensing condi­tions.

SURFACE

The ideal target surface is hard and smooth. This surface will reflect a greater
amount of signal than a soft, rough surface. A weak echo, which is the result of
a small or soft object, will reduce the operating distance of the sensor and
decrease its accuracy.

DISTANCE

The shorter the distance from the sensor to an object, the stronger the returning
echo will be. Therefore, as the distance increases, the object requires better
reflective characteristics to return a sufficient echo.

SIZE

A large object will have more surface to reflect the signal than a small one. The
surface area recognized as the target is generally the portion closest to the
sensor.

ANGLE

The inclination of the objects’ surface facing the ultrasonic sensor affects the
reflectivity of the object. The portion perpendicular to the sensor returns the
echo. If the entire surface is at a great enough angle, the signal will be reflected
away from the sensor and no echo will be detected.

Automation Products Group, Inc.

4

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A2, 11/08 IRU-2xx4/3xx4

DESCRIPTION

The IRU-2xx4/3xx4 is a low cost ultrasonic sensor used for non-contact measure­ment over a 1’ to 35’ range. RS-485 interface allows for convenient sensor
communication. The sensor is encased in a sealed chemical resistant housing
and has built in temperature compensation.

SPECIFICATIONS

IRU-2xx4 IRU-3xx4

Range: 1’ to 25’ 1.25’ to 35’

Housing: ABS or PVC PVC

Outputs: RS-485 & NPN RS-485 & NPN

Supply Voltage: 12 to 28 VDC 12 to 28 VDC

(24 VDC Recommended sensor performance
is diminished if lower voltage applied)

Current Draw: 60 ma @ 24 VDC 60ma @ 24VDC

2.0 Watts Max. 2.0 Watts Max.

Transducer Type Ceramic Ceramic

Ratings NEMA 4X NEMA 4X

Sensor adjust RS-485 interface RS-485 interface

Operating temp. -40 to 60 °C -40 to 60 °C

Resolution .1inches (2.5mm) .1inches (2.5mm)

Accuracy +/- 0.25% Range +/- 0.25% Range

Temp. Comp. Internal Internal

(thermistor located on transducer face)

Sample Rate Programmable, 1 to 22 Hz

Beam pattern 9 degrees off axis (when operating with

high sensitivity)

Cable 6 conductor, 22 gauge 6’ length

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

5

IRU-2xx4/3xx4 Rev. A2, 11/08

+1 2

GND

GND

T D(B )

T D(A )

RS-232 to RS-485
Converter

Orange Wire

Blue Wire

SETUP & OPERATION

Wire the IRU-2XX4/3XX4 as described below.

Color Description
Red + 12 - 24 VDC
Black Ground

Orange T(+) or TD(A)
Blue T(-) or TD(B)

White NPN (200 ma max)
Green Clock Sync.

RS-485 COMMUNICATIONS DATA

All Communication to the sensor is in the following format:

Protocol RS-485 2 wire
Speed 9600
Length 8 bits
Stop 1 bit
Parity none
Echo on

Automation Products Group, Inc.

6

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A2, 11/08 IRU-2xx4/3xx4

COMMAND PROTOCOL

A command must be sent to the sensor in order to obtain any information from
the unit.

• All distances coming form the sensor will be in whole millimeters.

• The temperature is returned as a Celsius value with a 40° positive offset

• No negative numbers, decimal numbers or fractions are sent.

COMMAND STRUCTURE

All of the IRU-2XX4/3XX4 commands follow the format below.
Messages from the sensor

Start character (AAh)
Sensor Number as single byte value
Command Number as single byte value
Data values as double byte value
Stop character (55h)

6 bytes Total

Messages from the sensor
Start character (66h)
Sensor Number as single byte value
Command Number as single byte value
Data value 0 as double byte value
Data value 1 as single byte value for returning distance and

temperature if possible

Stop character (99h)

7 bytes total

MEMORY

There are two types of memory available in the IRU-2XX4/3XX4, E2 and RAM.
E2 is nonvolatile and will retain the data if power to the sensor is lost or turned
off. RAM is volatile and will not be retained without power. The number of
WRITES available to E2 is approximately 10,000. Prudent use of this function
will allow a lifetime of use. The number of READS from E2 is unlimited. If
frequent parameter changes are anticipated or necessary, use the WRITE RAM
functions to avoid “wearing out” the E2 memory.

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

7

IRU-2xx4/3xx4 Rev. A2, 11/08

COMMAND LIST

COMMAND
01h) Read Sensor Number EE
02h) Write Sensor Number EE

03H) READ BANK NUMBER EE
04H) WRITE BANK NUMBER EE
05H) READ BLANKING EE
06H) WRITE BLANKING EE
07H) READ PULSES EE
08H) WRITE PULSES EE
09H) READ SENSITIVITY EE
0AH) WRITE SENSITIVITY EE
0BH) READ CALIBRATION EE
0CH) WRITE CALIBRATION EE
0DH) READ TEMPERATURE COMPENSATION
0EH) WRITE TEMPERATURE COMPENSATION
0FH) READ AVERAGE EE
10H) WRITE AVERAGE EE
11H) READ OUT OF RANGE SPAN EE
12H) WRITE OUT OF RANGE SPAN EE
13H) READ OUT OF RANGE COUNT EE
14H) WRITE OUT OF RANGE COUNT EE
15H) READ SAMPLE RATE EE
16H) WRITE SAMPLE RATE EE
17H) READ TRIP BEGIN
18H) WRITE TRIP BEGIN
19H) READ TRIP END
1AH) WRITE TRIP END
1BH) READ TRIP TYPE
1CH) WRITE TRIP TYPE
1DH) READ TRANSMIT OFF(0)/ON(1)
1EH) WRITE TRANSMIT OFF(0)/ON(1)
1FH) RESET PARAMETERS TO DEFAULTS
20H) START TRANSMIT SENSOR
21H) STOP TRANSMIT SENSOR
22H) START TRANSMIT BANK
23H) STOP TRANSMIT BANK
24H) DISTANCE AND TEMPERATURE READ

Automation Products Group, Inc.

8

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A2, 11/08 IRU-2xx4/3xx4

PARAMETERS

The Parameters (E) command displays the current settings of the sensor. The
following is an example of a parameter report from the IRU-2XX4/3XX4.

PARAMETERS MENU Min. Max.

Distance Sensor Number EE 0 9
Bank Number EE 0 9
Blanking EE 152 7620
Pulses EE 0 20
Sensitivity EE 0 100
Calibration EE 0100 1999 (0 .100 to 1.999)
Temp. Compensation 0 1
Average EE 1 10
Out of Range Span EE 0 7620
Out of Range Count EE 0 250
Sample Rate EE 23 1000
Trip point begin 0 7620
Trip point end 0 7620
Trip point type 0 7
Sensor Transmit 0 1 (0 = OFF, 1 = ON)

The IRU-2XX4/3XX4 will display the distance to a target in millimeters.

DISTANCE SENSOR

To request the Distance and temperature from sensor number 1, send:

Send Receive

AAh Start Byte 66h Start Byte
01h, Sensor Number 01h Sensor Number
24h Command 24h Command
00h Data (not used) ##h Distance (High Byte)
00h Data (not used) ##h Distance (Low Byte)
55h End Byte ##h Temperature

99h Stop Byte

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

9