Series 4000 LED Time Delay Plug-in Control Modules

Transcription

1 Installation Instructions Original Instructions Series 4000 LED Time Delay Plug-in Control Modules Catalog Numbers 22DJ9 Single Module Provides On or Off and On and Off Time Delay Functions Features opaque containers, to penetrate dirt, dust, smoke, haze, rain, and other similar obstructions. For use with PHOTOSWITCH pulsed LED sensors not affected by ambient light All solid-state, transient suppressed, plug-in, modular design reliability with flexibility All critical electronics on the plug-in function module not in the sensors Synchronous Detection circuit no response to adjacent LED controls or other extraneous noise Module circuitry includes unique circuit for visible LED alignment indicator on Light Source Adjustable Sensitivity application with different types of materials from semi-transparent to dense materials Transmitted Beam, Reflected Beam (Proximity) and Reflex Scanning Modes of presence sensing No false turn-on pulse Externally visible LED indicator on module signals operation and alignment Selection of Light or Dark energized mode of operation DPDT relay or solid-state logic outputs Multiple sensor combinations can be connected for parallel (OR) logic, or with an adapter, for series (AND) logic Range Extender #63-70 adds additional sensitivity and material penetration power. Description The PHOTOSWITCH Series 4000 Time-delay Control modules are designed for use with either the Series 4000 LED Control Base (see Bulletin PA-7411) or the Series 3000 Universal Control Base (see Bulletin PA-7311) for general control applications involving detection, inspection, counting, positioning, sorting, starting or stopping, monitoring, etc. In addition to the above standard photoelectric applications, the introduction of the pulsed LED Light Source has increased the application solving capabilities of this control by positioning the light source and receiver on the same side of the object so they operate in a Proximity mode. In this mode, objects or material levels can be detected by bouncing the light beam directly off the material. The use of LED infrared sensing also makes it possible to detect objects in The solid-state modular plug-in concept of the Series 4000 Control Modules was created with reliability and flexibility in mind. It simplifies pre-engineering for layout purposes and minimizes down time for field changes. Positive contract, gold-plated connectors from the plug-in Control Module to the Control Base help ensure operational reliability. Proper alignment of the mating connectors is assured by insertion guides on the Control Base, and, once in position, the module becomes positively latched in. Unlatching for removal or inspection is easily accomplished by hand, with no tools required. All Series 4000 LED controls utilize synchronous detection circuitry, which restricts the control to operation only from its own pulsed LED light source. Sensors from different controls can now be mounted close together without concern of the possibility that the receiver will sense the wrong LED light source. In addition, this unique circuit reduces the possibility of false operation due to extraneous random noise. Adjustable sensitivity is also provided, allowing the control operating level to be set for varying operating conditions, such as detecting semitransparent materials, small objects, etc. The input circuit is designed

2 also to prevent false output operation when power is first applied or is restored after momentary power failure making this control ideal for counting applications. All the LED modulation and demodulation electronic circuitry is part of the plug-in Control Module and the source/receiver sensors contain only the basic LED transmitting and detecting elements. By locating all critical electronic circuitry in the plug-in Control Module, instead of in the sensors, which are generally mounted online in an area subject to mechanical or environmental damage, sensor costs and physical size can be kept to a minimum. A visible red LED indicator is also mounted on the plug-in Control Module to signal when the output is energized. Its brilliance is proportional to the output current drawn. This Output Indicator also functions as an Alignment Indicator and is extremely useful for control and system testing at the control location. In addition, the plug-in Control Module includes a unique circuit that signals a visible LED indicator in the rear of certain types of PHOTOSWITCH LED light sources to indicate alignment with its receiver, without need for additional wiring. The Type 40CA4 Model 4000 Miniature Light Source, typically includes this online indication feature. The Series 4000 plug-in Control Modules provide circuitry to energize the DPDT relay output in either the light energized or dark energized mode. Selection is made via a dark light switch on the Control Module. Also, a 17V DC voltage signal at 30 ma is available when the DPDT output relay is removed. See Wiring Diagrams on page 4 for proper connections. Plug-in solid-state outputs are available as Accessories (to be used in place of the DPDT relay). The #63-65 Open Controller Logic Output will interface the Series 4000 control with solid-state systems utilizing TTL, RTL, DTL, and CMOS logic. The #63-64 DC Output Adapter provides a logic output of 17V DC at 30 ma and 20V DC at no load. This Output Adapter is used for interfacing the Series 4000 controls for gating functions, feeding into high speed counters, opto-isolators or other solid-state logic. Time Delay Type 22DJ9 Models 4000 & 4001 PHOTOSWITCH Series 4000 LED Time Delay plug-in Control Modules are universal in design in that a single module provides the choice of adjustable ON delay, OFF delay, or ON and OFF delay operation. This versatility is obtained by arranging the operation so that if either time delay adjustment is set to zero, the delay will be truly zero and the response will then be instantaneous. The Type 22DJ9 Series 4000 controls combine very high sensitivity with relatively fast response of 1 millisecond. It operates with large changes in light beam intensity, ignoring small changes, such as those caused by objects vibrating in the beam. The differential (light change necessary to activate the control) is 80 %. The Type 22DJ9 Series 4000 controls operate in either the light energized (L) or dark energized (D) mode set by setting the switch on the module to either LT or DK position. Light Energized Relay Energized with LED Beam on the Photodetector On Time LED beam restoration (alignment indicator lit) sustained longer than the preset on time delay will cause the output relay to be energized. LED beam interruption during the on time will reset the timing circuit and prevent the relay from being energized. Timing will begin again when the LED beam is restored. Off Time LED beam interruption (alignment indicator dark) longer than the preset off time delay will cause the output relay to be deenergized. Interruptions shorter than the preset off time will reset the timing circuit and prevent the relay from being de-energized. Dark Energized Relay Energized with LED Beam Interrupted On Time LED beam interruption (alignment indicator dark) sustained longer than the preset on time delay will cause the output relay to be energized. LED beam interruptions shorter then the preset on time will reset the timing circuit and prevent the relay from being energized. Off Time LED beam restorations (alignment indicator lit) longer than the preset off time delay will cause the output relay to be deenergized. LED beam restorations shorter than the preset off time will reset the timing circuit and prevent the relay from being de-energized. See Bulletin PA-7421 for data on types 22DJ3 and 22DJ4 on-off modules. Technical Specifications Series 4000 LED Time Delay Plug-in Control Modules Characteristics Type 22DJ9 Model 4000 Type 22DJ9 Model 4001 Differential percent change in photodetector resistance (or light change) Sensitivity Turn Down Adjustment 50 1 Response Time Voltage Output sec. Time Range On Delay with rated accuracy sec sec Recycle Time On Delay 0.1 sec 0.01 sec Time Range Off Delay with rated accuracy sec sec Recycle Time Off Delay 0.1 sec 0.01 sec Relay Output (Time Delays set to 0 ) sec Timing Repeatability Time Delay Variation with Temperature with Line Voltage Ambient Temperature Relative Humidity 90 % Maximum Operating Range ±1 %, Constant volts and temperature Not more than 20 % from C ( F) Not more than 10 % from V 0 57 C ( F) Operating ranges will vary depending on light sources, receivers, or scanners used. See page 3 and Application Information on pages 6 & 8 of this Bulletin. 2 Rockwell Automation Publication 4000-IN003A-EN-P - June 1986

3 LED Light Sources, Receivers and Scanners Miniature Side View Sub-miniature End View Features NEMA 3, 4, 12, and 13 corrosion resistant housings to withstand caustic cleaning solutions Visible LED alignment and operation indicator on light source and scanner Choice of standard or high sensitivity receiver Operating temperatures range from C ( F) Ten foot vinyl-jacket, shielded cable Conduit adapter assembly (# ) as accessory Range extender #63-70 increases range and penetration power Maximum Operating Ranges See Application Information on page 6. A. Using Type 40CA4 Model 4000 LED Light Source Receiver 22DJ9 Model 4000 & 4001 Transmitted Beam 27CN m (40 ft) + # m (200 ft) 47CN m (110 ft) Proximity Beam 47CN m (5 ft) + # m (8 ft) B. Using Type 42RC1 Scanner Receiver 22DJ9 Model 4000 & 4001 Reflex Beam 42RC # mm (3 in.) target To 9 m (30 ft) at max. control sensitivity mm (1 1/4 in.) target /8 target Consult factory + 3M #7600 tape + 3M #7590 tape 42RC mm (3 in.) target To m (60 ft) at max. control sensitivity Proximity Beam 42RC m (0.5 7 ft) Features NEMA 3, 4, 12, and 13 stainless steel corrosion resistant housing Housing is only xx mm (0.25 in.) in diameter to fit in tight places Operating temperatures range from C ( F) Ten foot vinyl-jacket, shielded cable Range extender #63-70 increases range and penetration power Universal mounting assembly # available as accessory Explosion proof housing, NEMA 7 and 9, # available Maximum Operating Ranges See Application Information on page 6. Using Type 40VY1 Model 4000 LED Light Source Receiver 22DJ9 Model 4000 & 4001 Transmitted Beam 47BU m (5 ft) + #63-70 adaptor 7.6 m (25 ft) Proximity Beam 47BU # m (12 ft) 1. Reflected beam (Proximity) mode ratings shown for separate light source and receiver are based on side by side mounting. 2. When using Type 42RC Reflex Scanner, the minimum operating range to Retro Target should be xx mm (4 in.). To Retro Tape the minimum range should be xx mm (6 in.). 3. When the Type 42RC1 Model 4000 Reflex Scanner is used in conjunction with Types 22DJ4 and 22DJ9 Control Modules, the operating range is set by adjusting the control sensitivity potentiometer. It should be noted, by trial and test, that increasing the sensitivity setting towards maximum to obtain longer operating ranges will also increase the minimum object distance necessary to avoid white paper response. 4. When the Type 42RC1 Model 4000 Proximity Scanner is used in the reflex mode with the Types 22DJ3, 22DJ4, and 22DJ9 control modules, the same information (as mentioned in Note 3) applies. 5. Consult the factory when the required cable lengths exceed m (100 ft). For extended cable runs, order the required footage by the following catalog numbers: # cable for Type 42RC1 # cable for Type 47BU1 # cable for Type 47BY1 # cable for Type 42CA4 # cable for Type 47CN4 Rockwell Automation Publication 4000-IN003A-EN-P - June

4 Wiring Diagrams When Using Sub-miniature 40-BY1 and 47BU1 Sensors 47BU1/4000 and 40BY1/4000 to LED Bases 47BU1/4000 and 40BY1/4000 to Incandescent Bases 1. Receiver housing must always be grounded. 2. Do not ground light source shield or terminal Receiver housing is connected internally to its cable shield, so shield will be automatically grounded. 4. Light source housing is not connected internally to its cable shield. It may be grounded but its grounding is not required. 5. For extended runs (beyond 3 m (10 ft), see Note 5 on page Use these connections with relay output only since power supply negative is not grounded. If solid-state output is required and LED base cannot be used, consult factory for special wiring instructions. 2. Do not ground LED light source shield or terminal For extended runs (beyond 3 m (10 ft), see Note 5 on page 3. When Using All Other Miniature and Sub-miniature Sensors 40CA4/47CN4 Combination LED Light Source/Receiver Pairs Scanners 1. Ground receiver housing (machine ground OK). 2. Ground terminal For extended runs, see Note 5 on page 3. 4 Rockwell Automation Publication 4000-IN003A-EN-P - June 1986

5 Installation and Wiring Mounting Receivers, light sources, and scanners can be mounted in any position, but they must be securely and rigidly mounted to a firm, stable surface or support. Mounting to surfaces subject to shifting or vibration may cause unsatisfactory operation (see Alignment section). Precaution must be taken when mounting and adjusting the Type 40CA4 light source, Type 47CN4 receiver, or Type 42RC1 scanner. Forcing or twisting the housing will cause possible damage to the unit. Wiring All wiring must conform to applicable provisions of the National Electric Code as well as local regulations. Rigid or flexible conduit may be used for interconnection of units, but rigid conduit, for maximum electrical shielding and physical protection, is recommended for extensions of light source, receiver, and scanner wiring. All PHOTOSWITCH Series 4000 circuits are filtered to reduce the effects of transients, but since all electronic circuits are susceptible in some degree to extraneous noise, care should be taken to avoid unnecessary coupling of transients into the circuit. The most efficient method of wiring the Series 4000 control is to bring the line voltage and output leads in from the top and low voltage leads in from the bottom. IMPORTANT Alignment Do not run receiver photodetector leads in the same conduit as the line voltage wires. Alignment is performed with the light source and receiver (or scanner) mounted and wired to the Control Base and with plug-in Control Module inserted. For transmitted light applications, align the receiver to look squarely at the light source and adjust the light source for proper alignment. The LED light source beam is factory aligned to be perpendicular to the mounting surface. Turn the sensitivity adjustment to maximum and align the light source to the receiver until the alignment indicator light goes out. Then realign the light source to the receiver until the alignment indicator light goes on again. Then do the same with the Receiver. With optimum alignment thus achieved, at low sensitivity, the sensitivity adjustment may be returned to maximum, with the control ready for operation with a large operating margin assured. If even more precise alignment is required, a 20,000 ohms/volt meter (6 or 10 volt scale) may be used with the Test Jack on the module. 1. A. For Type 22DJ9 with codes lower than 8000, connect meter negative lead to Test Jack. Meter position to terminal B. For Type 22DJ9, with codes 8000 or later, connect meter positive lead to Test Jack. Meter negative to terminal With the control operational, the meter reading will indicate the signal level received at the control input. 3. As the signal increases, the voltage increases with the output trip point (energize or de-energize) at about 4.6 volts and maximum volts. 4. To determine the Operating Margin (excess signal), reduce the sensitivity of 4.0 volts. The sensitivity adjustment scale reduction made indicates the amount of operating magin available. 5. Precise alignment may be achieved by reducing the sensitivity adjustment to a point at which optimum alignment (maximum signal) provides a meter reading of less than 5 volts. This permits observing the rise and fall of the meter with adjustment of the alignment. IMPORTANT 6. The output indicator light on the module indicates output energization and may also be used as an aid to beam alignment. It does not, however, show signal input to the control and should not be confused with the indication shown by the alignment indicator in the light source. Sensitivity Adjustment All Series 4000 controls include adjustable sensitivity. LED controls are not sensitive to ambient light. In most applications, therefore, the sensitivity potentiometer can be set for maximum (maximum clockwise position). Wiring Diagram See page 4 for proper connection of light sources, receiver, and scanners and see page 8 for range extender connections, if used. The meter reading will not exceed 6 or 7 volts, even though the signal increases after this point has been reached. IMPORTANT At short operating distances, the indicator may not go off when the sensitivity adjustment is set to zero. In this case, to further align the sensors, cover half the receiver lens. If the indicator stays on, the alignment is deemed adequate. In some applications, it may be necessary to use lens apertures to reduce sensitivity. 1. On Series 4000 Control Base only, output relay can be removed to obtain a 17V DC output signal across terminals 7 (+) and 8 (-). A maximum of 30 ma current is available if a 2.7 K ohms, 1/2 watt resistor is connected across 7 and 8. ATTENTION: No internal reverse polarity or transient protection is provided on the 17V DC output. Do not run leads with those carrying line voltage. Rockwell Automation Publication 4000-IN003A-EN-P - June

6 Transmitted Pulsed LED Beam Sensing Operating Range Selection The maximum operating ranges shown in the Technical Specifications are based on installation of the LED light source and receiver in a relatively clean environment. Experience tells us, however, that very few such ambient conditions exist in industry and the more normal industrial environment actually tends to cover the spectrum of classifications from moderately dirty to extremely dirty. The dirtier the environment, the greater the operating margin (or factor of safety) required to be used thereby limiting the operating range of the light source/receiver combination. This results in reduced operating range ratings as ambient conditions deteriorate. The chart below shows the relationship between operating margin (factor of safety) at various percentages of the maximum range at which the receiver will operate the control. For most relatively dirt-free applications, the operating margin should be at least 4X, indicating that a reliable operating range rating for a receiver should be 50 % or less of its maximum (point T 1 on the chart). If the application is relatively dirt free, this derating should be sufficient. For moderately dirty applications, the operating margin should be about 25X, reducing the operating range to 20 % of its maximum (see point T 2 on the chart). Dirty applications tend to require an operating margin of 100X, which requires that the operating range be reduced to 10 % of maximum for reliable receiver response. Extremely dirty applications require even futther reductions in operating range and in certain extreme cases, the receiver will not detect the pulsed LED beam at all. control, when the light source and receiver are mounted side by side, or when a scanner is used. For most relatively dirt-free applications, the Operating Margin (Factor of Safety) should be at least 3X, indicating that a reliable operating range rating for the receiver should be directed to 83 % or less of its maximum (point P 1 on the chart below). For moderately dirty environments, the operating margin should be about 25X, which reduces the reliable operating range to % of its maximum (see P 2 on the chart). In extremely dirty applications, proximity detection may not be satisfactory at all because of the poor efficiency of diffuse reflection. Miniature 42RC1 Scanners Parallel (OR) Logic Applications Proximity (Reflected Beam) Sensing The principle of LED modulation makes Proximity detection practical. The light source and receiver sensor combination can be mounted to bounce the beam off an object and back in to the receiver. It is not necessary that the material be reflective and it can be any color from white to black. The operating range will be greater with lighter color materials. Also, it will be greater if the light source and receiver are mounted adjacent to each other but they can be mounted at various angles with each other and still provide satisfactory results, depending upon the application. A scanner, which includes the LED source and receiver elements in a single housing, operates in the same manner. Proximity (Reflected Beam) Sensing Operating Range Selection The chart below shows the relationship between operating margin (Factor of Safety) at various percentages of maximum operating range at which the receiver will reliably detect the LED beam and operate the 6 Rockwell Automation Publication 4000-IN003A-EN-P - June 1986

7 Miniature 40CA4 Source/ 47CN4 Receiver Parallel (OR) Logic Connections Two (2) Sensors Sub-miniature 40BY1 Source/ 47BU1 Receiver Parallel (OR) Logic Connections Two (2) Sensors Three (3) Sensors Three (3) Sensors Four (4) Sensors Four (4) Sensors Parallel (OR) Logic Applications Multiple LED light souce/receiver combinations or scanners can be connected in a parallel (OR) logic circuit so that any one beam may be established (light energized mode) or all beams must be interrupted (dark energized mode) to energize the output relay. To achieve parallel (OR) logic, the light sources/receivers or scanners are connected in series, as shown above. Series (AND) Logic Applications To achieve Series (AND) logic, the light source/receiver combinations or scanners are connected to the four input logic adapters (#63-77), which connects directly to the Control Base. Up to four LED Light Source/Receiver combinations or scanners can be wired to the four-input Logic adapter to perform various logic combinations, selectable via three toggle switches. Refer to Bulletin A-7918 for detailed information on the use of the #63-77 adapter. Solid-state Plug-in Logic Outputs PHOTOSWITCH can provide plug-in output devices, as accessories (to be used in lieu of standard DPDT plug-in relays) for all Types 22 and 23 Series 3000 and 4000 Photoelectric controls. Catalog Number Open Collector Logic Output This plug-in output device provides capability for directly interfacing any Type 22 and 23 Photoelectric controls with solid-state systems utilizing TTL, RTL, DTL, CMOS logic. This open collector device can also be used to drive electromechanical counters. Refer to Bulletin PA-8202 for specification details. Catalog Number DC Output Adapter This output device provides a logic output of 17V DC minimum at a maximum current or 30 ma and 20V DC at no load when used with the Type 22 and 23 Photoelectric controls. It permits direct interfacing of controls for gating function, feeding into high speed counters, opto-isolators or other solid-state logic, thus eliminating electromechanical relay response delays contact bounce, etc. Refer to Bulletin PA-8202 for specification details. Rockwell Automation Publication 4000-IN003A-EN-P - June

8 Application Information Catalog Number Range Extender Adapter The PHOTOSWITCH #63-70 Range Extender adapter is a small pre-amplifier assembly designed to be inserted between any LED receiver and the signal input (receiver) terminals on any Control Base. Its effect is to significantly increase the signal level input to the control and thereby extend the operating range and penetrating power of the receiver. It is a means of maximizing the capabilities of the photoelectric control system at minimum additional cost. For further details regarding application and installation, see Bulletin PA Types 40CA4 and 47CN4/4002 and 4003 to #63-70 Range Extender Adaptor Wiring Diagram 47CN Series Receiver 40CA Light Source Ground by Contact with Frame Shield Jumper #63-70 All Control Bases Plug-in Control Module Shield 1. Ground receiver housing (machine ground OK). 2. Ground terminal Jumper terminal S of #63-70 to terminal 2 of base. 4. Strip back light source an inch or two and twist red and white leads tightly, right up to terminals 3 and For extended funs (beyond 10 ft), see Note 5 on page 3. R B 2 1 S R W #63-70 Range Extender Adapter Types 40BY1 and 47BU1 Sub-miniature to #63-70 Range Extender Adaptor Wiring Diagram Series 4000 LED* Control Bases Only 47BU #63-70 Receiver 40BY Light Source Shield Twist 1. Receiver housing must always be grounded. 2. Ground terminal S to same ground as receiver mounting bracket. 3. Receiver housing is connected internally to its cable shield, so shield will be automatically grounded. 4. Do not ground light source shield or terminal Light source housing is not connected internally to its cable shield. It may be grounded but its grounding is not required. 6. To avoid electrical coupling to range extender, strip back light source cable an inch or two and twist the red and white leads tightly, right up to terminals 3 and On extended runs (beyond 10 ft), see Note 5 on page For Series 3000 incandescent control bases which do not contain a terminal marked 8, run the ground jumper from terminal S to terminal 2. Only the plug-in relay output may be used since the power supply negative is not grounded. These bases may be modified for solid-state output. Consult factory for instructions. 2 1 S R Plug-in Control Module W * See note Rockwell Automation maintains current product environmental information on its website at Allen-Bradley, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat: İçerenköy, İstanbul, Tel: +90 (216) Publication 4000-IN003A-EN-P - June 1986 PA-7431 Copyright 1986 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.