Rockwell Automation 42DR User Manual
Installation/Configuration Instructions for 42DR
Intrinsically Safe Sensor
IMPORTANT: SAVE THESE INSTRUCTIONS FOR FUTURE USE.
Specifications
Normal Operation Requirements
Voltage Supply 13--29.5V DC
Supply Current 26mA max (output energized) at 13V DC
Response Time 1ms
Dual Outputs 1 NPN open collector (current sink)
Output Ratings 20mA, 29.5V DC maximum
Turn On Pulse Suppression Yes
Light/Dark Energized Option Yes
Reverse Polarity Protection Ye s
Output Overvoltage
Protection w/ Barriers
Field of View Type 42DRU Reflex 2.5
Sensitivity Adjustment Selectable by LOW (L)—HIGH (H) switch.
Ambient Temperature -- 4 0 F to 150F(--40Cto65C)
Relative Humidity 90%
Rated Operating Distances
42DRU- 5500 3 Dia. Reflector #92--39 1 to 30
42DRU- 5700 3 Dia. Reflector #92--39 6 to 15
42DRP- 5500
White Paper
Distance Discrimination Range
Distance differential between surface to be detected and background is defined
as the increase in distance required to de-energize the output, measured from the
point of energization:
Min. differential 10% 6 to 16
Min. differential 20% 2 to 5
42DRA- 5500 Operating distance depended on the choice
30mA max (output energized) at 29.5V DC
1 PNP open collector (current source)
Yes
Type 42DRP Proximity 3
Covers full range of operating distances.
All operating distances are with LOW (L)—
HIGH (H) switch in the HIGH (H) position.
1.25 Dia. Reflector #92--47 1 to 20
0.625 Dia. Reflector #92--46 1 to 15
1.25 Dia. Reflector #92--47 6 to 8
Short Range (SR) Long Range (LR)
1 5
5 to 16 16 to 5
of lens or Fiber Optic Cable. See Bulletin
PA- 8306, PA- 8307, and PA- 8401.
Features (continued)
S Photohead and terminal base are specially keyed to
prevent improper installation of non-intrinsically safe
equipment in a hazardous location.
S Terminal base for input voltages 13 to 29.5V DC eliminates
needs for separate junction box.
S Entity approval:
-- Vmax = 29.5V
-- Imax = 107mA
-- C i = 0 F
-- L i = 0 H
Attention: These parameters must be adhered to. If
!
not, injury may be caused to person or
property.
S Control input parameters
-- Supply voltage 13 to 29.5V DC
-- Supply current, 26mA max. at 13V DC, 30mA max. at
29.5V DC
S Plug-in Photohead contains functional electronics and
optics.
S Thick film microcircuitry for quality and reliability.
S Adjustable input sensitivity.
S RF interference protected.
S No false turn-on pulse.
S Synchronous detection circuitry avoids ambient
interference.
S Switch selection for light or dark operation.
S Dual open collector outputs provide current sink (NPN) and
current source (PNP) capabilities.
-- Load voltage 29.5V DC max.
-- Load current 20mA max.
S Response Time: 1ms
S LED alignment indicator: Visible 360
S NEMA 4X corrosion resistant, high impact housing.
S UL Listed.
Attention: Installation in hazardous environment
locations shall be made according to
!
ANSI/ISA -- RP 12.6 and other applicable
codes and standards.
Features
S For use in Class I, II, III; Division 1, 2; Group A, B, C, D, E,
F, G hazardous locations with Intrinsic Safety Zener Diode
Barriers.
S Reflex, polarized reflex, proximity, and special function
control models.
S Rated operating ranges
-- R e f l e x 1 to 30 (0.03m to 9m)
-- Polarized Reflex 6 to 15 (0.15m to 4.5m)
-- Proximity 0 to 5 (0 to 1.5m).
S Quick-Disconnect (QD) reduces downtime. No disruption of
alignment or wiring.
Attention: Substitution of components may impair
!
intrinsic safety.
Why Intrinsically Safe
Explosion prevention is a prime cons ideration in plants and facilities containing
hazardous atmospheres where “explosion-proof” housings are used.
The main fault with the “explosion-proof” housing system is that a single human
error could create a light explosion probability. Such occurrences as, failing to
tightly replace covers on “explosion-proof” housings, failing to shut off the power
before removing the cover of such a housing, and damaging the machined
surfaces of such covers are all prime examples.
Intrinsically Safe systems are now recognized as a more highly desirable
means of providing automated control functions in explosive environments. The
technique relies on the inherent parameters of electronic circuits, so that no
energy can be released under normal or abnormal operating conditions, of
sufficient magnitude to ignite a specified atmospheric mixture.
To design an effective Intrinsically Safe system, energy sources that enter the
hazardous area must be limited. For electronic controls, energy limiting is
accomplished by controlling the voltages and currents that may enter the
hazardous area. In addition, stored electrical energy in the controls is limited to
levels that cannot cause ignition of a given atmosphere.
An Intrinsically Safe system overcomes the shortcomings of the
“explosion-proof” system and virtually eliminates the probability of explosion by
properly installing Intrinsic Safety Zener Diode Barriers in the safe area.
Intrinsic Safety Zener Diode Barriers must be installed in the power supply
line,theload supply line and when using the current source (PNP) open
collector of the Series 5500,inthesignal return line.
Summary of Hazardous Locations
(For full and complete definitions, consult the National Electric Code
publication NFPA No. 70-- 78.)
Class I Locations in which flammable gases or vapors
are or may be present in the air in quantities
sufficient to produce explosive or ignitable
mixtures.
Class II Locations which are hazardous because of the
presence of combustible dust.
Class III Locations which are hazardous because of the
presence of easily ignitable fibers or flyings, but
in which such fibers or flyings are not likely to be
suspended in air concentrations sufficient to
produce ignitable mixtures.
Division I Locations which are hazardous concentrations
in the air exist continuously, intermittently, or
periodically under normal operating conditions.
Division 2 Locations which are hazardous concentrations
are handled, processed, or used but are
normally within closed containers or closed
systems from which they can escape only in
case of accidental rupture or breakdown.
Group A Atmospheres containing acetylene.
Group B Atmospheres containing hydrogen, or gases or
vapors of equivalent hazard, such as
manufactured gas.
Group C Atmospheres containing ethyl-ether vapors,
ethylene, or cyclo-propane.
Group D Atmospheres containing gasoline, hexane,
naptha, benzine, butane, propane, alcohol,
acetone, benzol, laquer solvent vapors, or
natural gas.
Group E Atmospheres containing metal dust, including
aluminum, magnesium, and their commercial
alloys, and other metals of similarly hazardous
characteristics.
Group F Atmospheres containing carbon black, coal or
cake dust.
Group G Atmospheres containing flour, starch, or grain
dusts.
Typical Class I Locations
S Petroleum refineries and gasoline storage and dispensing
areas.
S Industrial firms that use flammable liquids in dip tanks for
parts cleaning or other operations.
S Petrochemical companies that manufacture chemicals from
gas and oil.
S Dry cleaning plants where vapors from cleaning fluids can
be present.
S Companies that have s praying areas where they coat
products with paint or plastics.
S Aircraft hangars and fuel servicing areas.
S Utility gas plants, and operations involving storage and
handling of liquified petroleum gas or natural gas.
Typical Class II Locations
S Grain elevators, flour, and feed mills.
S Plants that manufacture, use, or store magnesium of
aluminum powders.
S Plants that have chemical or metallurgical processes,
producers of plastics, medicines, and firewoods, etc.
S Producers of starch or candies.
S Spice-grinding plants, sugar plants, and cocoa plants.
S Coal preparation plants and other carbon-handling or
processing areas.
Typical Class III Locations
S Textile mills, cotton gins, cotton seed mills, and flax
processing plants.
S Any plant that shapes, pulverizes or cuts wood and creates
sawdust or flyings.
Note: Fibers and flyings are not likely to be suspended in the
air, but can collect around machinery or on lighting fixtures
and where heat, a spark or hot metal can ignite them.
Series 5500 Type 42DRP Photohead and
42DTB Power Base with Covers Removed
Sensitivity
Adjustment
Low - High
Sensitivity
Switch
Light/Dark
Switch
SENS
LO HI
DK LT
TWO - WAY
TIME DELAY
O
N
O
F
F
Visible
Alignment
Indicator
Short Range
Long Range
Shutter
(on 42DRP
only)
PNP & NPN
Output
Circuitry
3
2
1
See page 7, for actual connection diagrams.
(+)
(- )
2
Description
Type 42DR Series 5500 QD Intrinsically Safe miniature self-contained
Photoelectric controls each consist of a combination modulated LED light
source, high speed silicon photodetector and dual open collector sold state
outputs which can be used to interface with programmable controllers,
computers, digital control systems or E-M control relays via Intrinsic Safety
Zener Diode Barriers.
The Type 42DR Series 5500 controls are modular in design and consist of two
components—a plug in photohead and a power base which are selected to
suit your functional requirements and assembled together at the point of
installation. The photohead includes a unique Quick-Disconnect feature so that
it can be quickly mounted to or removed from the power base by simply turning
one screw, without disrupting control wiring or alignment. This capability reduces
production downtime and replacement cost and precludes the need for adding
plug and cable assemblies for field disconnect purposes.
Please note that the Series 5500 photoheads and the Series 5500 power base
are keyed so that no other photohead other than the Series 5500 can be
mounted to the Series 5500 power base in a hazardous location. The user
must disconnect the power before removing the quick-disconnect
photoheads or covers.
All Type 42DR Series 5500 (5700) Photoelectric controls must be used
with Intrinisic Safety Zener Diode Barriers.
Photoheads
There are four different photoheads available. For reflex operation (with
retroreflective target), use Type 42DRU Model 5500 which provides an
operating range from 1 to 30.Forpolarized reflex operation (with corner
cube type retroreflective target), use Type 42DRU Model 5700 which provides
an operating range from 6 to 15.Forproximity operation (diffuse reflection
off the object itself), specify Type 42DRP Model 550 which offers an operating
range from 0 to 5. The design of Type 42DRA Model 5500 special function
photohead increases the application capabilities of the control line in difficult
environmental conditions by use of fiber optics and special lens assemblies.
In all models, the photohead contains all the functional electronics and optics. It
includes synchronous detection circuitry which tends to restrict the control to
operate only with its own pulsed LED source. Adjustable input sensitivity
broadens control application capability to those involving translucent and even
transparent materials, such as plastic films and glass. A switch is provided to
assure sensitivity adjustment over the entire control operating range.
With a flick of a switch, the Type 42DR control provides operation in either a
light energized (beam break) or dark energized (beam make) mode.
An optical shutter on the Type 42DRP proximity control permits the use of a
single control for both short- and long-range proximity applications. With the
shutter in the short range (SR) position, the maximum operating distance is 1.
The very sharp drop off in operating margin as shown in the Type 42DRP
response curve on page 6 helps to ignore backgrounds that are close to the
object being detected.
The dual open collector outputs, one an NPN open collector for current sink
and the other a PNP open collector to provide current source, are included in all
Type 42DR controls to maximize customer logic interconnection capabilities.
Therefore, these controls provide the opportunity for simultaneous connection to
relay loads or opto-coupler drives and TTL logic outputs. Seepage7for
connection diagrams.
Ordering Instructions
1. Select Power Base
Base Type
Terminal 13 to 29.5V DC 42DTB- 5500
2. Select Photohead
Operating Mode
Reflex
Polarized Reflex 42DRU- 5700
Proximity 42DRP- 5500
Fiber Optic
Wide Angle
Fixed Focus
3. Select Mounting Assembly
#60--1785 Universal, general purpose, 360 adjustment.
#60--1748 Heavy Duty, for mechanical protection.
#60--2014 Flexi-Mount, for Unistrut mounting on conveyor rails.
#60--2083 Photoguard, #12 gauge cold rolled steel heavy duty protection.
4. Select Intrinsic Safety Zener Diode Barriers
Select Control Drawing on page 7 for wiring diagrams of sourcing and
sinking output configurations. Barrier selection is described below for
each Control Drawing configuration. For installations, to ensure safety
each Barrier must comply with the entity parameters indicated on the
Control Drawing.
In selecting the Intrinsic Safety Zener Diode Barriers, it is important to consider
the resistance of the barrier to ensure operational characteristics in the midst of
inherent barrier voltage drop.
Voltage Supply Type & Model
Output
Characteristics
NPN (Current Sink)
and
PNP (Current Source)
Type & Model
42DRU- 5500
42DRA- 5500
Power Base
Type 42DRU, 42DRP, and 42DRA Intrinsically Safe models 5500 and 5700
Photoheads can be plugged only into a terminal base Type 42DTB Model
5500 suitable for voltage inputs of 13 to 29.5V DC.
The Type 42DTB Model 5500 Terminal Base allowstheusertomakehis
incoming and outgoing connections directly to the control thereby eliminating the
need of a separate junction box. Wiring connections are made to easy-to-wire
pressure type terminals with nonrotating clamps on the screws capable of
handling up to two #14AWG wires.
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