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Sensor Technology and Application Basics Reference Manual

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Sensor Technology and Application Basics Reference Manual Reference Manual Original Instructions Sensor Technology and Application Basics Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards. Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice. If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence. IMPORTANT Identifies information that is critical for successful application and understanding of the product. Labels may also be on or inside the equipment to provide specific precautions. SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Table of Contents Sensor Application Basics . 5 Contact vs. Non-Contact Technologies. 5 Discrete vs. Analog Detection . 6 Sensor Characteristics/Specifications . 6 Standards . .8 Agency Approvals. 9 Sensor Selection — A Methodical Approach . .10 Outputs & Wiring . 15 Power Supplies . .15 Output Types . .16 Wiring . .22 Output Timing and Logic . .26 PHOTOSWITCH Photoelectric Sensors . 29 Introduction. .29 Photoelectric Sensor Construction . .29 Sensing Ranges. .34 Sensing Modes. .39 Transmitted Beam . .40 Transmitted Beam Advantages and Disadvantages . .42 Typical Transmitted Beam Applications . .43 Retroreflective and Polarized Retroreflective . .44 Retroreflective and Polarized Retroreflective Advantages and Disadvantages . .47 Typical Retroreflective and Polarized Retroreflective Application . .48 Diffuse . .49 Diffuse Advantages and Disadvantages. .53 Fiber Optic Cables . .55 Inductive Proximity Sensors. 61 Standard Target for Inductive Proximity Sensors . .61 Target Correction Factors for Inductive Proximity Sensors . .62 Hysteresis (Differential Travel) . .62 Switching Frequency . .63 Ripple. .63 Mounting Considerations for Weld Field Immune Proximity Sensors . .63 Series Connected Sensors . .64 Parallel Connected Sensors . .65 TTL Wiring. .66 PLC Wiring . .66 Shielded vs. Unshielded Inductive Sensors . .67 Spacing Between Shielded Sensors (Flush?Mountable) and Nearby Metal Surfaces. .67 Spacing Between Unshielded Sensors (Nonflush?Mountable) and Nearby Metal Surfaces. .69 Applications. .72 Top 23 Reasons to Use the 871TM. .75 Ultrasonic Sensing . 77 Ultrasonic Sensor Construction. .77 Rockwell Automation Publication C117-RM001A-EN-P - February 2017 3 Table of Contents Sensing Range and Effective Beam. .78 Target Considerations. .82 Environmental Considerations. .84 Ultrasonic Advantages and Disadvantages. .85 Typical Applications . .86 Capacitive Proximity Sensors . 89 Shielded vs. Unshielded Capacitive Sensors . .90 Standard Target for Capacitive Proximity Sensors . .91 Environmental Considerations. .93 Capacitive Proximity Advantages and Disadvantages. .94 Typical Applications . .95 Limit Switches . 97 Limit Switch Construction . 101 Limit Switch Advantages and Disadvantages . 113 Typical Applications . 115 Encoders . 117 Incremental Versus Absolute Encoders . 118 Mechanical Installation and Accessories. 120 Applications. 122 Accessories . 122 Connection Systems. 125 Introduction. 125 Choosing the Best Cabling Option for Your Application. 126 Traditional Hardwiring Methods . 127 Wiring Consolidation Using Passive Distribution Boxes . 130 Safety Connection Systems . 132 Systems without Enunciation . 132 Systems with Enunciation ..
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