Massa MassaSonic PulStar/150 V Original operating instructions

MASSA PRODUCTS CORPORATION May 23, 2017
Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
PulStar®
Ultrasonic Sensors
Installation & Operation Guide
May 23, 2017
The PulStar Sensor product line listed in the introduction of this manual
complies with the European Council EMC Directive 2004/108/EC (EMC) and Low
Voltage Directive 2006/95/EC (LVD).
Copyright © 2016 by Massa Products Corporation. All rights reserved.

MASSA PRODUCTS CORPORATION May 23, 2017
Installation and Operation Guide MassaSonic™PulStar™Ultrasonic Sensors
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Table of Contents
Section Page
1 Introduction ........................................................................................................ 1
2 Quick Guide on Getting Started ..................................................................... 2
Mounting PulStar Sensors ................................................................................................................. 2
Operating a PulStar Sensor without a Computer .......................................................................... 2
Operating a PulStar Sensor Connected to a Computer ............................................................... 3
Operating Up to 32 Sensors Simultaneously Using a Multi-Drop Configuration ............................ 5
3Product Description ......................................................................................... 6
DC Power Requirements ................................................................................................................... 6
Voltage Output Models and Current Output Models .................................................................. 6
RS-485 Port ............................................................................................................................................ 8
4 Installing MassaSonic Software ....................................................................... 9
5 Status and Setup Screen .................................................................................. 10
Establishing Communication between a PC and a Sensor ........................................................... 10
Status Box of the Status and Setup Screen ...................................................................................... 11
Editing a Sensor’s Parameters ............................................................................................................ 12
Sensor Selection Box of the Status and Setup Screen .................................................................. 13
Mode Selection for Output Voltage (or Current Out) Box of the Status and Setup Screen . 14
Sampling Settings Box of the Status and Setup Screen ................................................................ 16
Miscellaneous Box of the Status and Setup Screen ....................................................................... 17
Messages Box of the Status and Setup Screen ............................................................................... 18
Self-Heating Correction ...................................................................................................................... 18
File Tab (Saving & Recalling Sensor Settings) .................................................................................. 19
Tools Tab (Calibration of the Voltage or Current Output) ........................................................... 20
Tools Tab (Firmware Update) ............................................................................................................. 21
Tools Tab (Ultrasonic Waveforms) .................................................................................................... 21
Setting Tab ............................................................................................................................................. 23
Getting Started Tab .............................................................................................................................. 24
6 Factory Default Programmed Settings ........................................................... 25
7 Specifications....................................................................................................... 25
8 Troubleshooting ................................................................................................. 26
9 Terminology ........................................................................................................ 26
10 Wire Color Code ................................................................................................ 28
11 Customer Support ............................................................................................. 28
12 Warranty ............................................................................................................... 28
Appendix A – Sensor Start Up Timing ....................................................................... 29
Appendix B – RS-458 Converters .............................................................................. 29

MASSA PRODUCTS CORPORATION May 23, 2017
Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
1
1 Introduction
The MassaSonic® PulStar® Ultrasonic Sensors combines Massa’s 70 plus years of experience in
electroacoustics with state-of-the-art analog and microprocessor hardware and software design. The
result is the most versatile, easiest to use ultrasonic sensor on the market. The PulStar Family of Sensors,
listed in the following table, consist of sensors that operate at different frequencies which determine
sensing range. For detailed ordering information, see website which includes options of various cable
lengths and PVC or PVDF housing materials.
Family of PulStar™ Ultrasonic Sensors
Model
Nominal
Ultrasonic
Frequency
System
Beam
Angle
Output Type Sensing
Range
PulStar/150 V 150 kHz 8 º 0-10 V 4” to 7’
PulStar/150 PLUS V 150 kHz 8 º 0-10 V 4” to 9’
PulStar/150 I 150 kHz 8 º 0-20 mA 4” to 7’
PulStar/150 PLUS I 150 kHz 8 º 0-20 mA 4” to 9’
PulStar/95 V 95 kHz 8 º 0-10 V 12” to 13’
PulStar/95 PLUS V 95 kHz 8 º 0-10 V 8” to 20’
PulStar/95 I 95 kHz 8 º 0-20 mA 12” to 13’
PulStar/95 PLUS I 95 kHz 8 º 0-20 mA 8” to 20’
In operation, PulStar Sensors generate a high frequency ultrasonic pulse, measures the time it takes for
the reflected echo to return from a target, and then calculates the target distance using the speed of
sound. The value of the speed of sound, which is a function of temperature, is determined by the sensor
using its internal temperature probe. The distance to a target can be obtained from a sensor in a variety
of ways. For example, the sensor output can be a DC voltage (or current), the value of which is
proportional to the target distance, or the sensor can be programmed to produce a switched voltage
output at a user-determined target distance. Information regarding the target can be sent by an RS-485
communication link to a computer and displayed using the MassaSonic Software or from another host
device. See the
PulStar® and FlatPack® Serial Communications Guide for developing a custom host
device.
Key Features of PulStar Sensors include:
• Analog or Setpoint Switched Output
• Plug & Play Setup -
No Targets Needed
• Software Set Span and Zero -
No Pots or Pushbuttons
• Easy to use Setup Software Using Windows®10, 8, 7, and XP Systems
• Built-in Temperature/Sound Speed Compensation
• Up to 32 Sensors on RS-485 Multi-drop Loop
• Ultrasonic Waveforms Allowing Diagnosis of Measurement Issues
• Fault Detection and Reporting

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Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
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2Quick Guide on Getting Started
Mounting the PulStar Sensor
The PulStar Sensor Family is designed to be easily mounted by using the 1” NPT threaded shaft that is
part of the housing of each sensor. It can either be screwed into a 1” NPT tapped hole or it can be
mounted onto a flat plate and secured with a supplied locknut. An optional Mounting Bracket can also
be purchased, as shown in Figure 1.
Figure 1
Photograph of a Massa PulStar/150 Sensor Attached to an Optional Mounting Bracket
Operating a PulStar Sensor without a Computer
•Provide a 12 to 24 V DC Power Supply and keep it turned off at this time.
•Connect the sensor’s leads as shown in Figure 2. Sensors are programmed for factory default
setting. Applications may need setting adjustments which will require connection to the
RS-485 port (green and brown wires) and the MassaSonic Software (see Figure 3). Once
configured, the RS-485 wires can be removed.
•Turn the Power Supply ON.
•The DC voltage (or current) on the white lead will be proportional to the distance to the target
(sensor configured zero and span settings).
Figure 2
Wiring Diagram for a PulStar Sensor Used Without a Computer

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Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
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2Quick Guide on Getting Started (continued)
Operating a PulStar Sensor Connected to a Computer
•Download the MassaSonic Software from Massa’s website and install it into your laptop. See
Section 4 in this guide for details.
•Provide a 12 to 24 V DC Power Supply and keep it turned off at this time.
•Connect the sensor’s power leads as shown in Figure 3.If wiring the sensor’s Vout or Iout
lead, connect it as well.
•Obtain a USB/RS-485 converter (see Massa’s website for purchase) and follow instructions to
properly configure it to a laptop. Only plug it into your laptop’s USB port when indicated.
•Wire the sensor’s RS-485 green and brown wires as shown in Figure 3.
•Turn the Power Supply ON.
•Execute the
MassaSonic Software program. See instructions in Section 5 to find the USB port
if not found.
•The main page will appear as shown in Figures 4 (standard) & Figure 5 (Plus) when the sensor
is found. If the sensor was not found, you may have to select another communications port.
Use the drop-down menu ‘Settings’ then ‘Communications Port’ to select another port. Use
the ‘Tools’ drop-down menu and then ‘Search for Sensors’ to establish communications on
the new port.
•Point the sensor towards a target, such as a wall, to obtain a distance measurement.
•To change any of the sensor’s settings, move the mouse pointer and click on the field to be
modified. After all changes have been made, click on the ‘Program’ button. There is no limit
to the number of times the sensor can be reprogrammed. The sensor’s settings are non-
volatile and the programmed values will be retained even if power is lost.
•The PulStar Sensor can be adjusted for optimum performance in each application by adjusting
its settings. (See Section 5 for detailed information regarding utilization of these adjustment
features.)
NOTE: A termination resistor on the RS-485 network is not required.
Figure 3
Wiring Diagram for a PulStar Sensor Used with a Computer

MASSA PRODUCTS CORPORATION May 23, 2017
Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
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2 Quick Guide on Getting Started (continued) `
Figure 4
Example of the Status and
Setup Screen for a Standard
PulStar Sensor
Figure 5
Example of the Status and Setup Screen for a PulStar PLUS Sensor

MASSA PRODUCTS CORPORATION May 23, 2017
Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
5
2 Quick Guide on Getting Started (continued)
Operating Up to 32 PulStar Sensors Simultaneously in a Multi-Drop Configuration
Sensors that will be wired together on the same RS-485 bus will first require that each sensor be
programmed with its own unique ID Tag. This must be done one at a time before all sensors can be
wired together. Follow the steps below:
•Connect the each PulStar Sensor one at a time to a computer using the steps shown in the
previous section entitled “Operating a PulStar Sensor Connected to a Computer”. Use the
Change ID Tag button to program a unique ID Tag from 1 to 32 into each sensor.
•Once all sensors have been programmed, wire all sensors to the power and RS-485 bus as
shown in Figure 6.
•Restart the MassaSonic Software program to find all the sensors. Each sensor can be viewed
one at a time by selecting it the
ID Tag drop down list. Status will be displayed along with its
settings that may be reprogrammed. Diagnostic waveforms can be obtained using the drop
down menu.
Figure 6
Wiring Diagram for PulStar Sensors Using a Multi-Drop Configuration

MASSA PRODUCTS CORPORATION May 23, 2017
Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
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3Product Description
This section contains a general overview of the PulStar™ Family of Ultrasonic Sensors. For detailed
information on any specific sensor model, please refer to the datasheet located on the Massa website
(www.massa.com).
DC Power Requirements
PulStar Sensors are powered from 12 to 24 V DC sources, either batteries or power supplies, that are
capable of supplying currents of approximately 30 mA (Vout models) and up to 50 mA (Iout models).
The red and black wires of a sensor must be connected to the DC power, as shown above in Figures 2,
3, and 6.
Voltage Output Models and Current Output Models
The sensor’s white lead produces 0-10 V DC (Vout) for the voltage output models, and 4 to 20 mA (or 0
to 20 mA) DC (Iout) for the current output models. The value of the voltage or current output relates
to the measured distance to the target. Each type of sensor has two modes of operation. In the
Proportional Voltage or Current Output Modes, Vout or Iout are directly proportional to the Target
Distance. In the Switched Setpoint Voltage or Current Output Modes, Vout or Iout switches between
0 and 10 V or 0 and 20 mA based on the Target Distance falling within specific distance zones that are
programmed into the sensor as Setpoints. More detailed information regarding the use of these
operational modes is contained in Section 5.
Proportional Voltage Output Mode or Current Output Mode (‘Linear Mode’)
Figure 7 is a schematic illustration of the Proportional Voltage Output Mode or Current Output when
sensor is operating in the Linear Mode. A Zero distance and a Span distance that are anywhere within
the Minimum Sensing Range and Maximum Sensing Range of the sensor can be programmed into the
sensor. The values of Vout will then be proportional to the Target Distance in the zone between the
distances set for Zero and Span. If a target is any closer than the Zero distance, Vout (or Iout) will be
the voltage value that was programmed into sensor for the Zero distance. If the target is further away
than the Span distance, Vout (Iout) will be the voltage value (or current) that was programmed into the
sensor for the Span distance. If target is not detected, than Vout (or Iout) will be a third voltage setting
named “Loss of Echo Voltage” (or Current).
Figure 7
Schematic Illustration of the Proportional Voltage Output Mode of Vout or Iout

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Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
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3Product Description (continued)
In the ‘Linear Mode’, the user can set the values for the following programming options using the Status
and Setup Screen shown in Figure 4.
1) Set any Output Voltage value from 0 V DC to 10.25 V DC (or current from 0mA to 20.5 mA) for the
Zero Distance.
2) Set any Output Voltage value from 0 V DC to 10.25 V DC (or current from 0mA to 20.5 mA) for the
Span Distance.
3) Set any Output Voltage value from 0 V DC to 10.25 V DC (or current from 0mA to 20.5 mA) for the
No Echo Time Out to indicate that the target is “lost”, which occurs after the preset number of
samples that were programmed into the ‘No Echo Time Out’ in the ‘Sampling Settings’.
With this flexibility, positive or negative slopes can be established, along with any start and end voltage
value (or current). Targets within the detection zone, established by the Zero and Span distances, will
produce an output voltage (or current) that is proportional to the Target Distance between the Zero
Output Voltage and the Span Output Voltage.Targets detected beyond the endpoints of the selected
distance zone will produce output voltage (or current) equal to the nearer endpoint.Targets detected
closer than the minimum specified Sensing Range will produce a voltage (or current) equal to the
Outpoint Voltage programmed for the Zero distance. Targets detected at distances greater than the
programmed Span distance will produce a voltage (or current) equal to the Output Voltage (or current)
programmed for the Span distance. If no target is detected, a voltage (or current) will be the Output
Voltage (or current) programmed for ‘No Echo Time Out’.
Switched Setpoint Output Mode (‘Switch Mode’)
Figure 8 is a schematic illustration of the Switched Setpoint Output Mode (‘Switch Mode’) for the
sensor’s Voltage Output (or current). In this Switch Mode, a Close Setpoint Distance and a Far Setpoint
Distance, that are anywhere within the Minimum and Maximum Sensing Range, can be programmed
into a sensor. These two setpoint distances will then establish three distance zones, which are the CIose
Zone for Target Distances less than the Close Setpoint Distance, the Mid Zone for target distances
between the Close Setpoint Distance and the Far Setpoint Distance, and the Far Zone for Target
Distances greater than the Far Setpoint Distance. Voltage value of 0 V or 10 V (or 0 mA or 20 mA) can
be selected to be outputted when the target is located in each of the three zones.
Figure 8
Schematic Illustration of the Switched Setpoint Output Mode

MASSA PRODUCTS CORPORATION May 23, 2017
Installation and Operation Guide MassaSonic® PulStar® Ultrasonic Sensors
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3Product Description (continued)
In the SWITCH MODE SETTINGS section, program values to set up distance zones and output values
sensor will produce when target is in any specific zone. Follow these steps.
1) Enter a value for a Close Setpoint Distance.
2) Enter a value for a Far Setpoint Distance.
3) Select a value of voltage output 0 V or 10.25 V (or current output 0 mA or 2 0mA) when the target is
in the Close Zone (<Close Setpoint Distance).
4) Select a value of voltage output 0 V or 10.25 V (or current output 0 mA or 20 mA) when the target is
in the Mid Zone (>Close Setpoint Distance and <Far Setpoint Distance).
5) Select a value of voltage output 0 V or 10.25 V (or current output 0 mA or 20 mA) when the target is
in the Far Zone (>Far Setpoint Distance).
6) Select a value of voltage output 0V or 10.25 V (or current output 0 mA or 20 mA) if no target is
detected after set timeout (see setting “No Echo Timeout”).
7) The Mid Zone also has a ‘No Change’ programmable option where the value of Vout (or Iout) will
not charge when a target enters this zone from another zone.
8) Hysteresis around the setpoints can be programmed from 0% to 75%.
9) Output for target detected closer than the minimum specified Sensing Range will be the same as
the Close Zone.
RS-485 Port
Communicating with PulStar Ultrasonic Sensorsis done through the RS-485 serial communications
port. The advantages of an RS-485 based system include the ability to have long cable lengths and up
to 32 sensors on one pair of wires (multi-drop). This method allows for access to all sensors from any
convenient location. When communicating with a PC, a communications converter will be required to
convert the signals from the PC’s USB or RS-232 port to the sensor’s RS-485 port. Wire the PulStar
Sensor to the RS-485 Communication Converter as shown in Figure 3.
To learn more about the specific operational details of this communication port, see the
PulStar Sensors
Serial Communications Guide
located on the Massa website (www.massa.com).
Multi-drop Operation
If planning to connect more than one PulStar Sensor on the same communications bus, each must be
programmed with its own unique ‘ID Tag’ from 1 to 32. To do this, power and program each sensor
with its own unique ID Tag before wiring them together. The available ‘ID Tag’ numbers are 1 to 32.
The software will now allow the monitoring and editing of any sensor on-line. To monitor any sensor,
simply go to the ‘ID Tag’ field in the ‘Sensor Selection’ box and select a sensor by using the ‘ID Tag’
drop down menu and highlighting the numbering of the sensor that is to be monitored (Figure 16).