Acuity AccuRange AR500 User manual

AccuRange AR500™ Laser Sensor
User’s Manual
Revision 3.0 –For models with serial number 19300 or higher.
For use with AR500™ Laser Position Sensor
May 1, 2020
Acuity
A product line of Schmitt Industries, Inc.
2765 NW Nicolai St.
Portland, OR 97210
www.acuitylaser.com

2 AR500 Operation Manual
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AR500 Operation Manual i
Procedures for Obtaining Warranty Service
1. Contact your Acuity distributor or call Schmitt Industries, Inc. to
obtain a return merchandise authorization (RMA) number within the
applicable warranty period. Schmitt Industries will not accept any
returned product without an RMA number.
2. Ship the product to Schmitt Industries, postage prepaid, together
with your bill of sale or other proof of purchase. your name, address,
description of the problem(s). Print the RMA number you have obtained
on the outside of the package.
This device has been tested for electromagnetic emissions and
immunity and has been found to be in compliance with the
following directives for class A equipment:
EN 60825-1:2014
This device complies with part 15 of the FCC Rules. Operation is
subject to the following two conditions:
(1) This device may not cause harmful interference, and (2)
this device must accept any interference received, including
interference that may cause undesired operation.
Note: This equipment has been tested and found to comply with the
limits for a Class A digital device, pursuant to part 15 of the FCC rules.
These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications. Operation of this device in a residential area is likely
to cause harmful interference in which case the user will be required to
correct the interference at his or her own expense.
This manual copyright © 2020, Schmitt Industries, Inc.

ii AR500 Operation Manual
User’s Manual for the
AR500™ Series Laser Sensor
Rev. 3.0
Table of Contents
1. Introduction ........................................................................................................................ 1
1.1 General Overview....................................................................................................... 1
1.2 Definition of Terms ..................................................................................................... 2
1.3 Quick Start Instructions............................................................................................... 2
1.3.1 Mounting................................................................................................................. 2
1.3.2 Serial Data Wires.................................................................................................... 3
1.3.2.1 RS232 serial....................................................................3
1.3.2.2 RS485 serial....................................................................3
1.3.3 Analog Output Signals............................................................................................ 3
2. General Description............................................................................................................ 4
2.1 Principles of Operation ............................................................................................... 4
2.2 Mechanical Dimensions.............................................................................................. 5
2.3 Installation.................................................................................................................. 5
2.4 Laser Safety............................................................................................................... 6
2.5 Sensor Maintenance................................................................................................... 7
2.6 Sensor Service........................................................................................................... 7
2.7 Sensor Specifications................................................................................................. 7
3. Installation and Checkout................................................................................................... 8
3.1 Mounting..................................................................................................................... 8
3.2 Cabling for sensor unit................................................................................................ 8
3.2.1 Standalone Cabling ................................................................................................ 8
3.2.2 Serial Connection to a Host Computer.................................................................... 9
3.3 Power On ................................................................................................................... 9
3.3.1 Serial Communications Check...............................................................................10
3.3.2 Sensor Output Check.............................................................................................10
4. Signal and Power Interface ...............................................................................................11

AR500 Operation Manual iii
4.1 Sensor Cable, Wire Colors and Functions.................................................................11
4.2 Power Supply (Red, Brown).......................................................................................11
4.3 RS232 / RS485 Serial Comm. (Green, Yellow)..........................................................12
4.4 Analog Output (Blue, Grey)........................................................................................12
4.4.1 Current Loop..........................................................................................................13
4.4.2 Voltage Output.......................................................................................................13
4.5 Logic Outputs (Pink, Grey).........................................................................................14
5. Serial Interface Operation..................................................................................................15
5.1 Binary Communications Protocol and Syntax ............................................................15
5.1.1 Request.................................................................................................................15
5.1.2 Answer ..................................................................................................................16
5.1.3 Data Stream ..........................................................................................................17
5.1.4 Saving to Non-Volatile (FLASH) Memory...............................................................17
5.1.5 Recover AR500 Factory Settings...........................................................................17
5.2ASCII Communications Protocol................................................................................17
5.2.1 Saving to Non-Volatile (FLASH) Memory...............................................................17
5.2.2 Recover AR500 Factory Settings...........................................................................17
6. Analog Output Operation...................................................................................................17
6.1 Analog Output ON/OFF.............................................................................................18
6.2 Analog Output Mode..................................................................................................18
6.3 Analog Output Working Range..................................................................................19
7. Logic Interface(s) Operation..............................................................................................20
7.1 Binary Communication...............................................................................................20
7.2 ASCII Communication ...............................................................................................21
8. Performance Optimization.................................................................................................22
8.1 Baud Rate .................................................................................................................22
8.2 Laser ON/OFF...........................................................................................................22
8.3 Network Address.......................................................................................................22
8.4 Zero Point..................................................................................................................23
8.5 Sampling Mode..........................................................................................................23
8.6 Sampling Period........................................................................................................23
8.6.1 Output Rate...........................................................................................................24
8.7 Maximum Integration Time ........................................................................................24
8.8 Results Lock..............................................................................................................25
8.9 Results Averaging Mode............................................................................................25

iv AR500 Operation Manual
8.9.1 Averaging Configuration ........................................................................................26
9. Demo and Configuration Software.....................................................................................27
9.1 Program Setup ..........................................................................................................27
9.2 Connecting to the sensor (RS232/RS485).................................................................27
9.3 Sensor Operation ......................................................................................................28
9.4 Display and Archiving of Data....................................................................................29
9.5 Setting and Saving Sensor Parameters.....................................................................30
9.5.1 Setting Parameters................................................................................................30
9.5.2 Saving Parameters................................................................................................31
9.5.3 Saving and Writing a Group of Parameters............................................................31
9.6 Factory Reset............................................................................................................31
10. Serial Command Quick Reference ................................................................................32
10.1 Binary Communication Reference .............................................................................32
10.2 ASCII Communications Reference ............................................................................35
11. Accessories...................................................................................................................37
11.1 Protective Enclosure..................................................................................................37
12.2 Spray Guard..............................................................................................................38

AR500 Operation Manual 1
1. Introduction
This section is a guide to getting started with the AR500 and this manual. The
AR500 has a number of configurable parameters, but many applications can use
the sensor in its default factory configuration. This manual contains information
for a variety of AR500 sensor configurations that can be ordered from Acuity.
Your specific AR500 model may not have all interfaces and functions described in
this manual.
The recommended order for reading the manual is:
•General Overview –Gives a brief understanding of the sensor operation.
•Operating Guidelines –Provides a few important safety tips.
•Definition of Terms –An aid for proper communication.
•Quick Start Instructions –This should provide the information necessary to
connect the sensor and verify its operation, either with a serial terminal
program at 9600 baud, or by connecting the current loop or Alarm Output
interface.
•General Description –Gives important laser, operation, mechanical, and
mounting information.
•Installation and Checkout –Tailor the application. Use the other chapters
for reference:
Signal and Power Interface –how to hook everything up
Serial Interface Operation –modes, formats, bias
Analog Output Operation –current loop, voltage, scaling
Alarm Output Operation –alarm settings
Performance Optimization –Sample Rate, Background Elimination,
Exposure control
AR500 Command Set –explains all commands for customizing the
application
1.1 General Overview
The AR500 is a triangulation sensor that measures distance using a laser beam,
a camera, and a microprocessor. A variety of models are specified, each to
allow a different measurement range, communications interface, laser power
and environmental options. Models vary in range from 5 to 1000 mm.
Interface options include RS232, RS485, 4-20mA, 0-10V and Ethernet.
Sensors can be optionally ordered with an internal heater or air cooling jacket.
The accuracy is generally specified with a linearity of about +/- 0.10% of the
range.
A variety of configuration settings can be selected via the serial port or
Ethernet interface (available option). The complete list of settings is found in
the AR500 Command Set chapter and each setting is discussed in detail in a
specific operation chapter.
The Sample Rate can be specified and the sensor has capability above 9400
samples per second. Several other configurable parameters enhance the

2 AR500 Operation Manual
performance. Sampling may be turned on and off. It can even be triggered
using an input signal wire or a serial command.
After making changes to the configuration, it may be viewed, saved in non-
volatile memory, and restored. At power-on the sensor uses the most recently
saved configuration settings.
Do not attempt to disassemble the sensor or loosen any screws.
Improper disassembly will destroy the optical alignment of the sensor and
necessitate factory repairs.
Do not operate the sensor in areas Where: the sensor case is exposed
to direct sunlight for extended periods or Where: the air temperature
is more than 60C (140F) or less than -10°C (-14°F).The optional
internal heater or air-cooling jacket may extend these temperature limits
Don’t allow fast temperature variations during sensor operation.
Avoid excessive vibration and shocks. The sensor contains securely
mounted but precisely aligned optical components.
Do not operate the sensor if the lens is fogged or dirty.
Do not scratch the lenses on the front face of the sensor. Keep the
lenses clean with expert optical procedures. The lenses are glass with an anti-
reflection coating. Avoid the use of organic cleaning solvents.
Do not touch the lenses with bare fingers. The oils are very difficult to
remove.
Operate only with DC supply voltages between 9 and 36 volts.
1.2 Definition of Terms
Sensor –The complete AR500 measurement device.
Target –The object of measurement. The relative distance from the sensor to
the target is measured by the sensor.
Laser, Laser beam –This bright light is emitted from the sensor, reflected from
the target, and collected by the camera lens. For the AR500, it is visible
(Red or Blue) radiation or in some specially-ordered configurations,
infrared.
<Range> –The maximum relative distance measurable by the sensor.
Base Distance –The distance from the face of the laser to the start of the
measurement window (range).
1.3 Quick Start Instructions
This will get the sensor running in its factory default configuration.
Only one output type (Serial or Analog) is needed to indicate sensor operation.
1.3.1 Mounting
Quick suggestion: Lay the sensor on the floor or a table. It may need to be
held in place with a clamp or a weight. Orient the laser so that the laser is
not obstructed. Use a piece of paper such as a business card to insert into
the beam to use as a measurement target. The laser should be aimed at a

AR500 Operation Manual 3
target such that the distance from the reference point to the target can be
measured.
Mount the sensor in such a way that the case is not twisted or warped. The
AR500 can be screwed on using two fastening screws 3.6 /06x7. The
fastening screws are not included in the scope of delivery.
Attach the cable(s) 8-pin connector to the plug(s) on the rear of the sensor.
Connect the red (Supply +) and brown (Ground) wires of the sensor cable
to a 9 to 36 volt DC power supply (or use the power supply if the sensor
came with one).
1.3.2 Serial Data Wires
The serial connection is required to set up a unit for operation. If not using
the Acuity Connectivity kit which includes a serial cable, the customer must
make their own D-sub 9 serial connector
1.3.2.1 RS232 serial
Connect the RS232 wires to a 9 pin D-SUB male connector that can be
plugged into a COM port of a PC (RS232): Gray (Ground) to pin 5, Green
(Transmit) to pin 2, and Yellow (Receive) to pin 3. See section 0.
Use the Demo and Configuration Software (see Section 9) to connect to
the sensor via the serial port and get distance measurements.
1.3.2.2 RS485 serial
Connect the RS485 wires to a RS485 adapter connected to a PC COM port
Gray (Ground) to pin 5, Green (Data+) to pin 2, and Yellow (Data -) to pin
3. See section 0.
Follow the same instructions for RS232 serial above.
1.3.3 Analog Output Signals
Quick suggestion: connect a DVM (digital volt meter) to the wires: Gray to
Common, Blue to mA input. Type QA. The output is a 4-20mA current loop
from 0 to the maximum range. The meter should read near 4 mA when a
target is placed in the laser beam near 0 mm and 20 mA near the end of
the range

4 AR500 Operation Manual
2. General Description
The AR500 is an ultra-compact laser diode-based distance measurement sensor
with available ranges covering 5 to 1000 mm. Consult the AR500 data sheet for
exact model range availabilities. The accuracy is generally specified with an
absolute linearity of +/- 0.10% of the span with a resolution of 0.01% of the span
for ranges up to the 750 mm model, and an absolute linearity of +/- 0.15% of the
span with a resolution of 0.02% of the span for the 1000 mm range model.
Linearity will vary depending on sample averaging, temperature, target stability
and surface reflectivity of the target surface. The AR500 laser sensors can be
ordered with a variety of red, blue and infrared laser diodes and a variety of data
interfaces. The sensor can be triggered externally and also has logic outputs to
trigger alarms, etc.
2.1 Principles of Operation
The AR500 uses laser triangulation principles to measure distance. The laser
beam is projected from the housing’s aperture and shines on a target surface,
where it creates a small spot. From there, the laser light is scattered in all
directions for diffuse surfaces (mirrors reflect the light specularly). A collection
lens is located behind a window in the sensor. It collects a portion of the
reflected light, which is focused on a CMOS detector array. The linear position
of this reflected spot is converted to an electrical signal which is proportional
to the target distance relative to the sensor. The position is processed and
communicated via serial, analog, digital or Ethernet interfaces.

AR500 Operation Manual 5
2.2 Mechanical Dimensions
The following diagram shows the mechanical dimensions for the AR500. The
sensor unit has two Ø3.6 / Ø6x7 holes on the sides. On all models there is an
8 conductor supply cable (w/ a Binder series 712 8-pin connector). On models
without Ethernet, this cable is for power and all communications (serial,
analog, trigger, power, etc.). On models with Ethernet there is an additional
Ethernet cable (w/ a Binder series 712 4-pin connector) dedicated to Ethernet
data transmission. The outer case of the sensor is cast aluminum with
annodization for corrosion resistance.
2.3 Installation
The AR500 sensor unit is typically installed by affixing the sensor to a machined
bracket with bolts through the two mounting holes on the side of the sensor.
Their location is shown in the mechanical drawing in the previous section. Note
that the zero point is NOT the glass window, but instead a distance from the
glass window called the base distance. Most brackets will have adjustment
capabilities so the AR500’s laser can be aimed in X, Y and Z coordinates.

6 AR500 Operation Manual
2.4 Laser Safety
Installers of laser sensors should follow precautions set forth by ANSI Z136.1
Standard for the Safe Use of Lasers or by their local safety oversight
organization. The AR500 is a class 1 (eye safe) laser product as stipulated in
IEC 60825-1/DIN EN 60825-1:2001-11 and a class 2, 3R or 3B product under
FDA 21CFR.
Red Lasers
Blue Lasers
Infrared Laser
Figure 1 AR500 laser safety labels (all available diodes)

AR500 Operation Manual 7
2.5 Sensor Maintenance
The AR500 sensor and module require little maintenance from the user. The
sensor lens should be kept clean of dust buildup as a part of regular
preventative maintenance. Use compressed air to blow dirt off the windows or
use delicate tissue wipes. Do not use any organic cleaning solvents on the
sensor. If your sensor does not function according to specifications, contact
Schmitt Industries, Inc. Do not attempt to loosen any screws or open the
sensor housing.
2.6 Sensor Service
The AR500 sensor is not user-serviceable. Refer all service questions to
Schmitt Industries, Inc. Do not attempt to loosen any screws or open the
sensor housing.
2.7 Sensor Specifications
Units in mm unless noted.
Note: Specifications may change with future revisions.

8 AR500 Operation Manual
3. Installation and Checkout
3.1 Mounting
Mount the sensor in such a way that the case not twisted or warped. Do not
clamp or squeeze the sensor case excessively. If the case is distorted, the
sensitivity and accuracy of the sensor may be affected.
3.2 Cabling for sensor unit
The AR500 sensor has a multipurpose cable with 8 conductors (included).
Special-order Ethernet sensors will include a second cable with 4 conductors.
The standard cable is LiYCY (TP) a flexible, overall shielded, PVC twisted-pair
data transmission cable for use in flexible and stationary applications under
low mechanical stress with free movement without any tensile stress, loads or
forced movements in dry, damp and wet conditions. The twisted pair
construction reduces interference (crosstalk) within the cable while the tinned
copper braid shield offers optimum protection from electrical and
electromagnetic interference. The AR500 is not suggested for outdoor use.
The standard cable length is 2 m in length. Longer cable lengths are available
upon request. Connection and termination according to the instructions is
essential for correct sensor operation. Read the wire descriptions in Section
4.1 for connection information.
Connect the cable’s 8-pin connector (Binder series 712, female) to the plug
(Binder series 712, male) on the back cover of the AR500 sensor. Be sure to
tightly secure the connection for full protection from dust and water.
3.2.1 Standalone Cabling
To use the AR500 sensor unit without a serial connection to a host
computer, the only connections necessary are the power and ground wires,
the analog output wires, and optionally the alarm output wire connecting
to your data display, recording, or control equipment. See Signal and
Power Interface (section 4) for wire connections. In its default
configuration, the AR500 should stream measurement distances on power-
up.
In 4-20mA analog output mode, the best accuracy and linearity for the
current loop is obtained with a 500-ohm load to current loop return at the
measurement point. To reduce noise, it is recommended to install RC
(resistor-capacitor) filter before the measuring instrument. The filter
capacitor value is indicated (in section 4.4) for maximum sampling
frequency of the sensor (9.4 kHz) and this value increases in proportion to
the frequency reduction. An out-of-range current indicates a sensor
measurement error.
The alarm output wire can be used to connect to control equipment.

AR500 Operation Manual 9
3.2.2 Serial Connection to a Host Computer
The simplest way to connect the AR500 sensor to a PC for initial
configuration or regular distance measuring is with the use of an Acuity
Connectivity Kit. This is a sealed connection box which contains terminal
blocks for each wire lead. It also has an AC power supply and a 2m RS232
serial cable for connection to a PC. Without the Acuity connectivity kit, the
user must connect a DB9 plug to the cable using the directions below.
Each AR500 is configured for either RS232 or RS485 serial
communications. Please be sure to confirm the serial communication
standard used by the control system you intend to use before ordering. If
you have an AR500 with the incorrect standard for your application, a
third-party converter will be necessary.
RS232: An AR500 with the RS232 option can be wired directly to a 9-pin
D-sub serial connector using the table below.
Wire Color
Function
Binder 712 pin #
DB9 pin #
Gray
Ground
5
5
Green
TxD / Data+
3
2
Yellow
RxD / Data -
4
3
To connect the AR500 this way to a modern PC, you will likely need a serial
to USB converter. Acuity recommends using a converter that contains an
FTDI chip.
RS485: To wire an AR500 with the RS485 option to a 9-pin serial
connector, please refer to the wire functionality chart in section 4 for
details.
For testing use the included Demo and Configuration software. Refer to
section 9.
3.3 Power On
Connect a power supply to the power and ground lines of the sensor cable.
The AR500 can operate with a power supply supplying 9-36 volts. Acuity
recommends a 15 or 24 volt power supply. See Signal and Power Interface
(section 4) for wire connections. Only the power and ground need be connected
for operation in addition to the serial interface.
When power is applied the laser beam will be emitted from the round sensor
window.

10 AR500 Operation Manual
3.3.1 Serial Communications Check
If no information is received over the serial port, check the power supply
and serial wire connections. The sensor may be in a configuration that
prevents serial communication, such as being set at the wrong baud rate
or is in a polling mode.
Use the Demo and Configuration Software to restore the unit to factory
defaults. Otherwise, the 04h command will restore factory defaults to the
device.
3.3.2 Sensor Output Check
If the sensor output value is in error, check that the sensor and target are
stationary and stable and that the laser beam is hitting the target.
The sensor may need to warm up for 5-10 minutes before reaching
full accuracy. Leave it on for a few minutes and re-check the sensor
accuracy.

AR500 Operation Manual 11
4. Signal and Power Interface
4.1 Sensor Cable, Wire Colors and Functions
The AR500 sensor includes a multipurpose cable (sensor cable) with
solder tail wires. Connection and termination according to the
instructions is essential for correct sensor operation. Read the wire
descriptions for connection information.
71
2
3
4
8
6
5
Figure 2 AR500 cable with 8 conductors (Binder 712, #09-0427-80-08)
The tables below shows the wiring on systems ordered without power
supplies.
Wire
Pin
Function in All Modes
White
1
Trigger Input
Brown
2
Ground (Power)
Green
3
TxD (Data +)
Yellow
4
RxD (Data -)
Gray
5
Ground (Signal common)
Pink
6
Logic Output (programmable)
Blue
7
Analog output (current loop / voltage)
Red
8
Power, Voltage in
4.2 Power Supply (Red, Brown)
The Brown wire is the Power Supply Common return, also named Ground.
It carries the return current for the power supply.
The Red wire is the Power Supply Input to the sensor. The sensor requires
+9 - 36 VDC power and consumes 1.5 –2 Watts of power (< 250mA
draw) depending on the sensor’s configuration.
Power supplies from 9 VDC to 36 VDC may be used. Higher voltages will
result in excessive current drawn by the over-voltage protection circuitry
and may cause permanent damage. Voltages less than 9 VDC may result
in inaccurate measurement readings or non-functionality.

12 AR500 Operation Manual
4.3 RS232 / RS485 Serial Comm. (Green, Yellow)
Your sensor is configured with either RS232 or RS485 communications
See Serial Interface Operation (section 5) for information on commands
and data. The maximum baud rate is 921.6 KBaud for both RS232 and
RS485.
RS232: RS232 is normally used for shorter distances of communications
and slower data rates. RS232 allows only one transmitter and one
receiver per network. A standard 9-pin D-SUB RS232 serial female
connector can be built to interface with a PC or a serial to USB converter
using connection the pins below.
Color
Pin on DSUB 9
connector
Function
Green
2
Transmit data from sensor
Yellow
3
Receive data to sensor
Gray
3
Signal ground reference
N /C
1, 4, 6
DCD, DTE, DCE –These three signals
can be tied together to satisfy some PC
signal requirements for hardware
handshake.
N / C
7, 8
CTS, RTS –These two signals can be
tied together to satisfy some PC signal
requirements for hardware handshake.
RS485: RS485 is normally used for longer distances of communications
and faster data rates. Multiple devices can share one line because RS485
is multi-drop. If you do not have a computer or controller or PLC that
supports RS485 communications, it may be necessary to use a
commercial RS485 to RS232 converter.
4.4 Analog Output (Blue, Grey)
Your sensor is configured with either 4-20mA current loop or 0-10V
voltage analog output.
The Grey wire is the return signal for the Analog Output. It is connected
to ground inside the sensor and should not be connected to
ground outside the sensor. Inadvertently connecting it to ground may
cause a reduction in accuracy of the analog output. The analog signal for
distance is a 4-20 mA current loop or 0-10V signal.
In Current Loop / Voltage Blue wire delivers a current (or voltage for
sensor ordered with Voltage output) proportional to the measured
distance. The resolution is characterized by a 16-bit digital-to-analog
converter.

AR500 Operation Manual 13
4.4.1 Current Loop
The current loop connection scheme is shown in the Figure 3. The value of
load resistor should not be higher than 500 Ohms. To reduce noise, it is
recommended to install an RC (resistor / capacitor) filter before the
measuring instrument. The filter capacitor value is indicated for maximum
sampling frequency of the sensor (9.4 kHz) and this value increases in
proportion to the frequency reduction.
Figure 3 Wiring Diagram for Current Loop output
4.4.2 Voltage Output
The voltage output connection scheme is shown in the. To reduce noise, it
is recommended to install an RC (resistor / capacitor) filter before the
measuring instrument. The filter capacitor value is indicated for maximum
sampling frequency of the sensor (9.4 kHz) and this value increases in
proportion to the frequency reduction.
Figure 4 Wiring Diagram for Voltage output

14 AR500 Operation Manual
4.5 Logic Outputs (Pink, Grey)
The Pink wire is a multi-purpose logic output / interface that can operate
in eight distinct modes. The functionality can be configured according to
the instructions in section 7 . Functions include distance alarms, multi-
sensor synchronization, setting of Zero Point via hardware control,
encoder input, Ethernet packet counter reset, and control of the laser ON
/ OFF state.
See Alarm Output Operation (section 7) for operation options and details.
The Logic Output is an open collector NPN transistor switch to the Ground
for Signal (Grey). When the Alarm Output is not active, its output will be
high impedance and no current will flow through it. When the Alarm
Output is active (On) it can source up to 100mA of current. The voltage
on the Alarm wire must not exceed 24 VDC.
Distance Alarms
Multi-sensor Synchronization
Zero point set / Laser On / Off
control
Figure 5 Wiring Diagram
for Distance Alarms
Figure 6 Wiring Diagram
for Multi-sensor
synchronization
Figure 7 Wiring Diagram
for Zero point control and
Laser On / Off