MAYSER USi-PP User manual

Polymer Electric
GmbH & Co. KG
Polymer Electric
Örlinger Straße 1–3
89073 Ulm
GERMANY
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.mayser.com
Operating Instructions
Original instructions
Ultrasonic Industrial Sensor USi
Master Slave
USi-PP 1005632 * 1005633 *
USi-IP 1005899 * 100900 *
USi-UP 1005901 * 1005902 *
* plus Sensor 1005264
Version 03

Page 2/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Table of Contents
Inhaltsverzeichnis
About these operating instructions......................................................................................................................... 3
Intended use .............................................................................................................................................................. 5
Limits................................................................................................................................................................. 5
Safety instructions .................................................................................................................................................... 5
Applicable Standards......................................................................................................................................... 6
Parts supplied............................................................................................................................................................ 7
Transport and storage............................................................................................................................................... 7
Packaging and transport.................................................................................................................................... 7
Storage.............................................................................................................................................................. 7
Product overview....................................................................................................................................................... 8
Sensor (Ultrasonic Transducer) ......................................................................................................................... 8
Evaluation Unit .................................................................................................................................................. 8
LEDs information............................................................................................................................................... 9
Connections..................................................................................................................................................... 9
Unit Cable with M12 Socket (optional)............................................................................................................. 10
Sonic Lobe ...................................................................................................................................................... 10
Operation.................................................................................................................................................................. 12
Detection – the USi as a Switch (digital) ....................................................................................................... 12
Operating Mode 1Range...................................................................................................................... 12
Operating Mode 2Ranges.................................................................................................................... 12
Operating Mode Window....................................................................................................................... 13
Measuring – the USi as a Sensor (analog) ................................................................................................... 13
Operating Mode 1 Range...................................................................................................................... 13
Operating Mode Window....................................................................................................................... 14
Examples of Use ............................................................................................................................................. 15
Installation................................................................................................................................................................ 17
Mounting the Sensor (Ultrasonic Transducer) ................................................................................................. 17
Alternative: Enclosure set (optional)...................................................................................................... 18
Mounting the Evaluation Unit .......................................................................................................................... 18
Alternative: Mounting rail adapter (optional).......................................................................................... 19
Wiring the Unit Cable....................................................................................................................................... 19
Commissioning........................................................................................................................................................ 21
Initialisation...................................................................................................................................................... 21
Correlation............................................................................................................................................. 21
Testing the Function ........................................................................................................................................ 22
Adjust Settings ........................................................................................................................................................ 23
Teach In: Teach in Environment.......................................................................................................................23
Adjusting the Switch Points ............................................................................................................................. 23
Logon/logoff Sensor 2 ..................................................................................................................................... 25
Copyright
The reproduction, distribution and utilization of this document as well as the communication of its contents wit-
hout express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reser-
ved in the event of the grant of a patent, utility model or design.
© Mayser Ulm 2014

281114 v1.3 Operating Instructions USi Page 3/43
Polymer Electric About these Operating Instructions
Restore Factory Settings ................................................................................................................................. 26
Troubleshooting and remedies .............................................................................................................................. 28
Replacement parts .......................................................................................................................................... 31
Accessories ............................................................................................................................................................. 31
Maintenance and cleaning...................................................................................................................................... 33
Maintenance.................................................................................................................................................... 33
Cleaning .......................................................................................................................................................... 33
Decommissioning.................................................................................................................................................... 34
Disposal.................................................................................................................................................................... 34
Conformity ............................................................................................................................................................... 35
Factory Settings....................................................................................................................................................... 35
Technical Data ......................................................................................................................................................... 36
Glossary ................................................................................................................................................................... 38
About these operating instructions
These operating instructions are part of the product.
Mayser Polymer Electric accepts no responsibility or warranty claims for damage
and consequential damage due to failure to observe the operating instructions.
Read operating instructions carefully before use.
Keep operating instructions for the complete service life of the product.
Pass operating instructions on to every subsequent owner or user of the
product.
Add any supplement received from the manufacturer to the operating instruc-
tions.
These operating instructions are only valid for the products specied on the title
page.
Validity
The target group of these operating instructions are operators and trained specialist
personnel who are familiar with installation and commissioning.
Target group
In addition to the Operating Instructions, observe the following documents:
- Manual on Parameter Assignment Software for USi (optional)
Other applicable
documents
Technical terminology is alphabetically listed and explained at the end of the
Operating Instructions.
Glossary

Page 4/43 Operating Instructions USi 281114 v1.3
Polymer Electric
About these Operating Instructions
Symbol Meaning
... Action with one step or with more than one step where
the order is not relevant.
1. ...
2. ...
3. ...
Action with more than one step where the order is rel-
evant.
 ...
- ...
Bullets rst level
Bullets second level
(see Installation) Cross-reference
Symbols used
Symbol Meaning
DANGER Immediate danger leading to death or serious injury.
WARNING Imminent danger which may lead to death or serious injury
CAUTION Possible danger which may lead to slight injury or damage
to property.
Information on easier and safer working practices.
Danger symbols and
information

281114 v1.3 Operating Instructions USi Page 5/43
Polymer Electric Intended use
Intended use
The ultrasonic industrial sensor USi is designed for industrial use in the medium air.
It is comprised of the Evaluation Unit and up to 2 sensors (ultrasonic transducers).
It can be used to achieve the following functions:
 Reex switch
 Reex barrier
 Sonic barrier
 Analog distance detection
 Multisensor
Reex switches and reex barriers and Analog distance detection are possible us-
ing stand-alone (i.e. without parameter assignment software) master or slave units.
2 sensors (ultrasonic transducers) are required for the sonic barriers; several syn-
chronised USi (1 master + several slaves) are required to be multisensory.
Limits
 Safety-related tasks are not possible with the product.
 The use of the product in potentially explosive environments (ATEX) is not
possible. The product is not authorised for use in these areas.
 Objects with a highly sound-absorbing surface such as open-pore foam, cordu-
roy, etc., cannot be reliably detected.
 Objects with an extreme sound-dividing shape such as cone tip, or similar can-
not be reliably detected.
 Strong uctuations in temperature within very short periods of time cannot
counter balance the integrated temperature compensation.
Safety instructions
Do not open sensors (ultrasonic transducer)
Never open, manipulate or alter the sensors.
Do not squeeze the sensors
Avoid applying increased mechanical loads to the enclosure and the active
surface of the sensor (ultrasonic transducer).
Check supply voltage
Check supply voltage. It must correspond with the connecting voltage USspeci-
ed on the type plate.
Observe protection class
The Evaluation Unit only has protection class IP65 with carefully screwed on
screw plug and carefully tted lid.
Protect from sunlight
In the case of surface installation, ensure that the Evaluation Unit is protected
from direct sunlight.

Page 6/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Safety instructions
Applicable Standards
The type model of the product conforms to the EMC Directive 2004/108/EC.
Applicable standards:
 IEC60947-5-2 „IEC?60947-5-2 “Low-Voltage Switchgear and Controlgear –
Part 5-2: Control Circuit Devices and Switching Elements – Proximity Switches”
 IEC 60204-1 “Safety of Machinery – Electrical Equipment of Machinery; Part
1:General Requirements”
These Operating Instructions were drawn up in compliance with IEC 62079 “Prepa-
ration of Instructions – Structuring, Content and Presentation”.
In the event of a fault, take out of operation
In the event of malfunctions and visible damage, take the Control Unit out of
operation.
Do not overload Evaluation Unit
Ensure that the specied switching current is not exceeded.
Observe PIN assignment
Observe the PIN assignment when connecting the supply voltage.
Do not alter special cable
The special cable on the sensor (ultrasonic transducer) has a xed length.
Never shorten, lengthen or alter the special cable.

281114 v1.3 Operating Instructions USi Page 7/43
Polymer Electric Parts supplied
Store the parts of the USi in the original packaging in a dry place.
Observe the storage temperatures given in the technical specications.
Storage
The Evaluation Units are individually packaged in cartons. Several Evaluation Units
are stacked in one large carton.
The sensors (ultrasonic transducers) are packaged in a protective pressure lock
bag.
The documents are enclosed separately.
Packaging and transport
Transport and storage
Parts supplied
1×Evaluation Unit
Enclosure with electronics module.
1×Sensor (ultrasonic transducer)
1×Operating Instructions
1×Declaration of conformity
Check the scope of supply for completeness and the perfect condition of the pro-
duct immediately after receipt.
Required accessories:
1×Unit cable M12x8 / USi (optional)
You can nd recommended accessories in chapter Accessories.

Page 8/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Product overview
Product overview
Sensor (Ultrasonic Transducer)
The special cable between the ultrasonic transducer and the M8 plug has a xed
length of 1.5 m and may not be lengthened or shortened.
Should the 1.5 m not be sufficient, the cable length can be doubled using the
optional extension cable (1005903).
1 Ultrasonic transducer
2 Active surface
3 M8 plug
4 Shielded cable (1.5 m)
5 “Teach In” button
6 Fastening point (M4)
7 M8 socket: Sensor 2
Evaluation Unit
8 M8 socket: Sensor 1
9 Screw plug: Mini USB
10 M12 plug X1: Unit cable

281114 v1.3 Operating Instructions USi Page 9/43
Polymer Electric Product overview
7 M8 socket: Sensor 2
8 M8 socket: Sensor 1
9 Screw plug: Mini USB
10 M12 plug X1: Unit cable
Connection Type Explanation
X1 M12, 8-poled for Unit Cable
Mini USB 2.0 for parameter assignment via soft-
ware
Sensor 1 M8, 3-poled Sensor 1 (ultrasonic transducer 1)
Sensor 2 M8, 3-poled Sensor 2 (ultrasonic transducer 2)
Connections
Plug X1 Signal PIN Circular connector
Supply voltage +US
-US
2
7
M12
Output 1.1 OUT 1.1 1
Output 1.2 OUT 1.2 3
Output 2.1 OUT 2.1 4
Output 2.2 OUT 2.2 5
– (not assigned) – 6
Synchronisation SYNC 8
LEDs information
 Green LED “Power”:
supply voltage connected
 Yellow LED “OUT 1.1”:
Output 1.1 activated
 Yellow LED “OUT 1.2”:
Output 1.2 activated
 Yellow LED “OUT 2.1”:
Output 2.1 activated
 Yellow LED “OUT 2.2”:
Output 2.2 activated

Page 10/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Product overview
Unit Cable with M12 Socket (optional)
Cable for connection to downstream control system.
The Type LifYCY unit cable must be 8-poled (each lead min. 0.25 mm2), shielded
and equipped with an M12 socket.
Maximum length of the unit cable: 30 m.
Signal PIN Lead colour
Supply voltage +US
-US
2
7
BN
BU
Brown
Blue
Output 1.1 OUT 1.1 1 WH White
Output 1.2 OUT 1.2 3 GN Green
Output 2.1 OUT 2.1 4 YW Yellow
Output 2.2 OUT 2.2 5 GY Grey
– (not assigned) – 6 PK Pink
Synchronisation SYNC 8 RD Red
Earth – Transparent
Sonic Lobe
The following representations refer to the USi in delivery condition. Measurement
object: steel rod with Ø 10 mm. If parameters have been changed or if a different
measurement object is used, the representations will change accordingly.
Sonic lobe from the
narrow side and the
broad side
Reference axis

281114 v1.3 Operating Instructions USi Page 11/43
Polymer Electric Product overview
Sonic lobe spatially
Opening angle (-6 dB)
narrow side
Reference axis
Opening angle (-6 dB)
broad side
Reference axis

Page 12/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Operation
Operation
The ultrasonic industrial sensor USi uses the connected sensors (ultrasonic trans-
ducers) to both transmit and receive sound in the medium air. With a complex
measurement procedure, consisting of echo transit time measurement and echo
amplitude measurement, it is possible to reliably detect objects and also success-
fully measure distances accurately.
Outputs
Type Digital Analog Total
USi-PP PNP – 4×PNP
USi-IP PNP 4 to 20 mA 3×PNP 1×I [A]
ISi-UP PNP 0 to 10 V 3×PNP 1×U [V]
Detect Measure
Detection – the USi as a Switch (digital)
If switch point SP1 and switch point SP2 are dened, the USi begins detection in
the predetermined operating mode. The 3 possible operating modes are:
Operating Mode 1Range
Operating mode 1 Range is the preset standard operating mode.
SP1: 1 cm SP2: 200 cm
Since switch pointSP1 complies with the minimum switching distance of only 1cm,
detection is effectively from the active surface to the switch pointSP2. If an ob-
ject penetrates the detection eld, the outputs (preset as normally open contacts)
“OUTX.1” and “OUTX.2” are closed.
Operating Mode 2Ranges
If switch pointSP1 selection is larger than 1 cm, the USi-PP automatically changes
to operating mode 2ranges.
SP1: > 1 cm SP2: > (SP1 + 1 cm)
The detection eld is divided into 2 zones. The detection eld (red) that is sensor-
proximal extends effectively from the active surface to the switch pointSP1. The
sensor-distant detection eld (yellow) extends from the switch pointSP1 to the
switch point SP2. Each zone is assigned a separate output (preset as normally
open contact). If an object penetrates the detection eld (yellow), which is sensor-
distant, output “OUTX.2” will be closed. If an object penetrates the detection eld
(red), which is sensor-proximal, output “OUTX.2” will remain closed and output
“OUT X.1” will also be closed.

281114 v1.3 Operating Instructions USi Page 13/43
Polymer Electric Operation
Operating Mode Window
The operating mode Window can be exclusively selected via the parameter assign-
ment software (optional).
SP1: > 1 cm SP2: > (SP1 + 1 cm)
In contrast to operating mode 2 ranges, here the detection eld that is sensor-
proximal will not be visible. The detection eld that is sensor-distant still remains.
It extends from switch pointSP1 to switch point SP2. If an object penetrates the
detection eld far that is sensor-distant, the outputs (preset as normally open con-
tacts) “OUTX.1” and “OUTX.2” will be closed. If the object enters into the sensor-
proximal detection eld, the outputs “OUT X.1” and “OUT X.2” will be opened.
If the object laterally penetrates the sensor-proximal detection eld, the outputs
“OUT X.1” and “OUT X.2” will remain open.
Measuring – the USi as a Sensor (analog)
The measuring function is only available for USi with analog output. The 2 possible
operating modes are:
Operating Mode 1 Range
Operating mode 1 Range is the preset standard operating mode.
SP1: 1 cm SP2: 200 cm
Since switch point SP1 complies with the minimum switching distance of only 1 cm,
detection is effectively from the active surface to the switch point SP2. If an object
penetrates the detection eld, the outputs (preset as normally open contacts) “OUT
X.2” are closed. The distance from the detected object is converted to an analog
value and made available at the analog output “OUT1.1”:
OUT 1.1 Object at
Type no object SP1 (1 cm) SP2 (200 cm)
USi-IP 4 mA 4.8 mA 20 mA
USi-UP 0 V 0.5 V 10 V
The characteristic curve can also be inverted via the parameter assignment soft-
ware (optional).
Information: Upper limit in the blind zone. The USi has a blind zone of 10 cm
as a sensor. However, the switch point SP1 is preset to 1 cm, so that the full co-
verage range is simultaneously available to the USi as a scanner. Therefore, the
analog value for 10 cm is indicated on the analog output “OUT 1.1” for the range
up to 10 cm.

Page 14/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Operation
USi-IP
The distances determined by the sensor are indicated as analog current values
between 4.8 and 20 mA on output “OUT°1.1”. The linear progression results from the
even sub-division of the total measurement distance up to SP2. In the default set-
ting, this is 0.08 mA per centimetre.
USi-UP
The distances measured by the sensor are indicated as analog voltage values bet-
ween DC 0.5 and 10°V on output “OUT°1.1”. The linear progression results from the
even sub-division of the total measurement distance up to SP2. In the default set-
ting, this is 0.05 V per centimetre.
Operating Mode Window
If switch point SP1 is selected larger than 1 cm, the USi-IP automatically changes
to operating mode “Window”.
SP1: > 1 cm SP2: > (SP1 + 1 cm)
The sensor-proximal detection eld is not visible. The sensor-distant detection eld
extends from the switch point SP1 to the switch point°SP2. If an object penetrates
the detection eld further away from the sensor, the outputs (preset as normally
open contacts) “OUT X.2” are closed. The distance from the detected object is con-
verted to an analog value and made available at the analog output “OUT1.1”:
OUT 1.1 Objekt bei
Typ kein Objekt SP1 SP2
USi-IP 4 mA 4 mA 20 mA
USi-UP 0 V 0 V 10 V
The characteristic curve can also be inverted via the parameter assignment soft-
ware (optional).
USi-IP
The distances determined by the sensor are indicated as analog power values bet-
ween 4 and 20 mA at “OUT1.1”. The linear progression results from the even distri-
bution of the distance (SP2 - SP1).
Example: SP1 = 100 cm, SP2 = 200 cm. This results in 0.16 mA per centimetre
USi-UP
The distances determined by the sensor are be indicated as analog voltage values
between DC 0 and 10V at “OUT1.1”. The linear progression results from the even
distribution of the distance (SP2 - SP1).
Example: SP1 = 125 cm, SP2 = 175 cm. DThis results in 0.2 V per centimetre

281114 v1.3 Operating Instructions USi Page 15/43
Polymer Electric Installation
Examples of Use
Object detection
1. Simplest function: Is an object loca-
ted in the free detection eld?
2. Presence / absence monitoring: Does
the taught-in environment change?
1. Operating mode 1range.
2. Operating mode 1range and
teachin.
Conveying check
3. Flow check: Is the material to be con-
veyed present?
4. Quantity check: How many pieces
of material to be conveyed have gone
through?
5. Position check: Is the material to be
conveyed correctly positioned?
3. Operating mode 1range.
4. Operating mode 1range and down-
stream counter.
5. Operating mode 1range and
teachin.
Position detection
6. Position check: Is a dened position
reached?
6. Operating mode 1range and
teachin.
Distance detection
7. Distance check: When is a dened
distance not reached?
8. 2-zone observation: Has an object
penetrated Zone1 (from SP2 to SP1)?
For continued approach: Has an object
penetrated Zone2 (from SP2 to USi)?
7. Operating mode 1range and speci-
cation of the switch point SP2.
8. Operating mode 2ranges and speci-
cation of the switch points SP1 and
SP2.
Fill level monitoring
9. Fill level check: When is a dened ll
level not reached or exceeded?
10. Fill procedure check: If a certain
ll level (SP2) has been reached, then
continue to ll with lower ow volume. If
the nal ll level (SP1) is reached, con-
clude the ll procedure.
9. Operating mode 1range and speci-
cation of switch point SP2.
10. Operating mode 2ranges and
specication of the switch points SP1
and SP2.

Page 16/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Installation
Obstacle detection
11. Path check: Is the path taken unob-
structed?
12. Distance check: When is a dened
distance to the obstacle fall so far short
(SP1) that action must be taken?
11. Operating mode 1range.
12. Operating mode 2ranges and
specication of the switch points SP1
and SP2.
Area monitoring
13. Width of continuous surface: Is an
object located in the dened area?
13. Multisensory consisting of multiple
intersynchronised USi, thereof one
master.

281114 v1.3 Operating Instructions USi Page 17/43
Polymer Electric Installation
Installation
The installation includes three individual installation steps:
1. Mounting the sensor (ultrasonic transducer)
2. Mounting the Evaluation Unit
3. Wiring the unit cable
Mounting the Sensor (Ultrasonic Transducer)
The sensors can be mounted in any position.
If the sensors are supposed to be mounted in quiet workplaces or in areas where
there are hearing-sensitive animals, the interfering sonication must be considered.
Ultrasound is not audible for human beings. The “hard” transmission burst, however,
is perceived as a clearly audible crackle. At a measurement frequency of 20Hz
(typical), 20 crackles per second are audible. This can be stressful when continu-
ous. Here, it is recommended to not align the sensor directly to the ears, but at an
angle of at least 20°. The same applies for indirect sonication reected from hard
reectors like e.g. walls.
Alternatively, the transmission intensity can be altered via the parameter assign-
ment software (optional).
1. Place one O-Ring in each of the grooves N1 and N2 of the sensor. To do so,
select the corresponding O-rings for the specied mounting xture (see
below).
Standard mounting xture
– clamping version –
Optimised mounting xture
– integrated version –
Tolerances: ISO 2768-1 c Tolerances: ISO 2768-1 m
with O-rings 18.0 ×2.5 mm
Part number 7502819 (optional)
with O-rings 17.5 ×2.0 mm
Part number 7502820 (optional)
2. Mount the sensor (ultrasonic transducer) in any position in the mounting
brackets.
Sensor:
Dimensions

Page 18/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Installation
3. Lay the cable of the sensor at sufficient distance to sources of electromagnetic
interference, like e.g. direct current motors.
Malfunction due to incorrect mounting
Squeezing the sensor – particularly in the front area near the active surface – can
cause malfunctions and mechanical damage.
Only attach the sensor with the recommended O-rings.
Do not use the cable as a pulling aid. The cable can tear off.
Avoid high mechanical loads on the active surface (heavy pressure, impact,
etc.) when mounting.
Immediately replace damaged sensor (torn off cable, damaged active
surface). Repairs are not possible.
Alternative: Enclosure set (optional)
Instead of using your own brackets you can also use one of the Mayser enclosure
sets. See Chapter Accessories for a small selection. The installation steps are the
same as described above.
Mounting the Evaluation Unit
The Evaluation Unit can be mounted in any position. If the Evaluation Unit is to be
mounted in a splash water environment, the parameter assignment situation via
USB connection must be considered. If the screw plug is removed, the protection
class drops to IP20. The opening for the USB connection should therefore be con-
gured in such a way that it preferably faces down and not in the direction of the
source of the splash water. We recommend the installation of an additional splash
water protection during parameter assignment (guard plate, foil, or similar).
Fix the Evaluation Unit in any position with two screws Ø3mm.
CAUTION

281114 v1.3 Operating Instructions USi Page 19/43
Polymer Electric Installation
Screws with Ø4mm are also an option. For this, the lid of the Evaluation Unit
must be removed, the two screws inserted and the lid carefully replaced on the
Evaluation Unit. The screws are now captive.
When performing these actions, avoid touching and soiling the electronics.
Ensure the correct seat of the seal in the lid.
Alternative: Mounting rail adapter (optional)
1. Mount the mounting rail adapter with the enclosed self-cutting screws SK
M5x10 on the rear side of the Evaluation Unit.
2. Fix the Evaluation Unit in any position on a 35mm mounting rail IEC 60715.
Wiring the Unit Cable
Danger of injury due to electrocution!
Disconnect all devices and live parts in the immediate environment of the
power supply and protect them against being switched on again (see relevant
Operating Instructions).
Check whether all devices and parts are disconnected from the power supply.
Lead colour Signal USi-PP USi-IP USi-UP
Brown
Blue
+US
-US
DC 15 to 30 V
White OUT 1.1 max. 200 mA
max. DC 30 V DC 4 to 20 mA DC 0 to 10 V
Green OUT 1.2 max. 200 mA
max. DC 30 V
Yellow OUT 2.1 max. 200 mA
max. DC 30 V
Grey OUT 2.2 max. 200 mA
max. DC 30 V
Pink – – (nicht belegt)
Red SYNC (intern)
Shielding Earth
Wire the strands of the unit cable that have been equipped with wire and
sleeves.
Connect the shielding to a suitable grounding point
WARNING

Page 20/43 Operating Instructions USi 281114 v1.3
Polymer Electric
Installation
Failure due to incorrect wiring!
Carefully check the wiring.
Inspect the supply voltage.
CAUTION
Impaired operation due to missing grounding!
Carefully check the grounding
CAUTION