APG IRU Series Ultrasonic Sensors User Manual

The sensors operate on an input voltage range of 12 to 28 Volts DC with a maximum current draw of 80mA.
They provide output signals in the range of 4-20mA and NPN. The models listed are suitable for hazardous locations with specific ratings for different environmental conditions.

Chapter 2: Installation and Removal Procedures and Notes

Tools Needed:

Ensure you have the necessary tools for installation such as screwdrivers, mounting brackets, and electrical connectors.

Installation Notes:

Follow the provided installation notes carefully to ensure proper mounting and electrical connections. Incorrect installation may lead to safety approval issues.

Mounting Instructions:

Mount the sensor securely in the desired location as per the guidelines provided in the user manual. Ensure it is positioned correctly for accurate readings.

FAQ

Q: What should I do if my sensor is not providing accurate readings?
- A: If your sensor is not providing accurate readings, first check the installation to ensure it is mounted correctly and the electrical connections are secure. You may need to recalibrate the sensor following the instructions in the maintenance section of the user manual.

Q: Can I use these sensors in hazardous locations?
- A: Yes, the IRU Series Ultrasonic Sensors are suitable for hazardous locations. Refer to the hazardous location drawing and certification section in the user manual for specific details on usage in such environments.

MODELS

INTRODUCTION

Thank you for purchasing an IRU ultrasonic sensor from APG. We appreciate your business! Please take a few minutes to familiarize yourself with your IRU and this manual.

The IRU series is APG’s line of general purpose ultrasonic sensors. With a choice of operating ranges from just a few inches to as far as 50 feet, the IRU product line is designed to fit a wide range of industrial automation applications. Sensor adjustments, such as sensitivity and filtering options, are made by interfacing the sensor to a PC using an RST module and APG’s free Windows based programming software. IRU sensors incorporate internal temperature compensation for increased accuracy under varying environmental conditions. The sensors are housed in PC/PET or UV resistant ABS to seal out moisture and resist a wide range of chemicals.

Reading your label

Every APG instrument comes with a label that includes the instrument’s model number, part number, serial number, and a wiring pinout table. Please ensure that the part number and pinout table on your label match your order. The following electrical ratings and approvals are also listed on the label. Please refer to the Certificate of Compliance and Declaration of Conformity at the back of this manual for further details.

Electrical ratings

Input: 12 to 28 Volts DC, 80mA max; Outputs: 4-20mA, NPN
- Class I Division 2; Groups C, D T6
- Class I, Zone 2, Group IIB
AEx nA IIB T6: Ta: -30°C to 60°C; IP65

Ex nA IIB T6: Ta: -30°C to 60°C; IP65

IRU models: IRU-2423, IRU-2425, IRU-3433, IRU-3435, IRU-5413, IRU-5415, IRU-5423, IRU-5425.
Models listed are rated for Pollution Degree 2, Installation Category II.

Input: 12 to 28 Volts DC, 80 mA max; Outputs: 4-20mA, solid state relay, NPN
- Listed for General Purpose
- Ta: -30°C to 60°C;

IRU models: IRU-2002, IRU-2003, IRU-2005, IRU-2423, IRU-2425, IRU-3433, IRU-3435, IRU-5413, IRU-5415, IRU-5423, IRU-5425, IRU-5429, IRU-6429, IRU-9423, IRU-9425, IRU-9429
Models listed are rated for Pollution Degree 2, Installation Category II.

IMPORTANT: Your IRU must be listed above and installed as shown on drawing 9003066 to meet listed approvals. Faulty installation will invalidate all safety approvals and ratings.

WARRANTY

WARRANTY AND WARRANTY RESTRICTIONS

This product is covered by APG’s warranty to be free from defects in material and workmanship under normal use and service of the product for 24 months. For a full explanation of our Warranty, please visit https://www.apgsensors.com/resources/warranty-certifications/warranty-returns/. Contact Technical Support to receive a Return Material Authorization before shipping your product back.

SPECIFICATIONS AND OPTIONS

Dimensions

Specifications

IRU-200X and 242X

IRU-343X

IRU-54XX

IRU-642X1

IRU-942X

Electrical Connectors and Pinout Tables

IRU-2002

3/C Cable	IRU-XXX3-C
Red	+24 VDC
Black	DC Ground
White	4-20 mA Out

4-pin MC	IRU-XXX3-M
1 Brown	+24 VDC
2 White	Not used
3 Blue	DC Ground
4 Black	4-20 mA Out

6/C Cable	IRU-2004-C	IRU-2005-C
Red	+24 VDC	+24 VDC
Black	DC Ground	DC Ground
Green	Clock Sync	Clock Sync
White	NPN trip	NPN 2
Blue	T (+) or (A)	NPN 1
Orange	T(-) or (B)	4-20 mA Out

5/C Cable	IRU-XXX5-C	IRU-XXX9-C
Red	+24 VDC	+24 VDC
Black	DC Ground	DC Ground
White	NPN 1	Voltage Out
Orange	4-20 mA Out	Excitation
Green	NPN 2	Analog Ground

5-pin MC	IRU-2004-M	IRU-2005-M	IRU-XXX5-M	IRU-XXX9-M
1 Brown	+24 VDC	+24 VDC	+24 VDC	+24 VDC
2 White	T (+) or (A)	NPN 1	NPN 1	Voltage Out
3 Blue	DC Ground	DC Ground	DC Ground	DC Ground
4 Black	T(-) or (B)	4-20 mA Out	4-20 mA Out	Analog Ground
5 Grey	NPN trip	NPN 2	NPN 2	Excitation

IRU-2003

8/C Cable	IRU-XXX9S-C
Red	+24 VDC
Black	DC Ground
Orange	Excitation
White	Voltage Out
Green	Analog Ground
Brown	RS-232 Ground
Yellow	RS-232 TX
Blue	RS-232 RX

8-pin MC	IRU-XXX9S-M
1 White	Voltage Out
2 Brown	+24 VDC
3 Green	Analog Ground
4 Yellow	RS-232 TX
5 Grey	RS-232 Ground
6 Pink	RS-232 RX
7 Blue	DC Ground
8 Red	Excitation

Model Number Configurator

The IRU sensor series offers a wide range of housing, outputs, and performance specifications.
Please refer to each sensor family’s datasheet for a full list of available configurations. Datasheets can be found at https://www.apgsensors.com/resources/product-resources/data-sheets/.

Model	Range	Frequency	Mounting	Output
2002	1-25 ft / 0.3-7.6 m	69kHz	Surface/Screws	(1) Solid-State Relay
2003	1-25 ft / 0.3-7.6 m	69 kHz	Surface/Screws	Isolated 4-20mA
2004	1-25 ft / 0.3-7.6 m	69 kHz	Surface/Screws	RS-485, 1 NPN Trip
2005	1-25 ft / 0.3-7.6 m	69 kHz	Surface/Screws	4-20mA, 2 NPN Trip
2009S	1-25 ft / 0.3-7.6 m	69 kHz	Surface/Screws	0-2.5/0-5 VDC, RS-232
2423	1-25 ft / 0.3-7.6 m	69 kHz	2” NPT Threads	4-20mA
2425	1-25 ft / 0.3-7.6 m	69 kHz	2” NPT Threads	4-20mA, 2 NPN Trip

3433	1.25-50 ft / 0.4-15.2 m	43 kHz	3” NPT Threads	4-20mA
3435	1.25-50 ft / 0.4-15.2 m	43 kHz	3” NPT Threads	4-20mA, 2 NPN Trip

5413	0.33-6.56 ft / 0.1-2.7 m	143 kHz	1” NPT Threads	4-20mA
5415	0.33-6.56 ft / 0.1-2.7 m	143 kHz	1” NPT Threads	4-20mA, 2 NPN Trip
5419	0.33-6.56 ft / 0.1-2.7 m	143 kHz	1” NPT Threads	0-2.5/0-5 VDC
5423	0.33-6.56 ft / 0.1-2.7 m	143 kHz	2” NPT Threads	4-20mA
5425	0.33-6.56 ft / 0.1-2.7 m	143 kHz	2” NPT Threads	4-20mA, 2 NPN Trip
5429	0.33-6.56 ft / 0.1-2.7 m	143 kHz	2” NPT Threads	0-2.5/0-5 VDC

6429	1-30 ft / 0.3-9.1 m	69 kHz	2” NPT Threads	0-2.5/0-5 VDC
6429S	1-30 ft / 0.3-9.1 m	69 kHz	2” NPT Threads	0-2.5/0-5 VDC, RS-232

9423	0.5-35 ft / 0.2-10.7 m	50 kHz	2” NPT Threads	4-20mA
9425	0.5-35 ft / 0.2-10.7 m	50 kHz	2” NPT Threads	4-20mA, 2 NPN Trip
9429	0.5-35 ft / 0.2-10.7 m	50 kHz	2” NPT Threads	0-2.5/0-5 VDC
9429S	0.5-35 ft / 0.2-10.7 m	50 kHz	2” NPT Threads	0-2.5/0-5 VDC, RS-232

Wiring Diagrams

IRU-2003 Isolated 4-20 mA Source Wiring

The IRU-2003 is equipped with an isolated 4-20 mA output. This means that the 4-20 mA circuit can be powered by the 4-20 mA signal receiver or a source independent of the receiver. An isolated source must be wired correctly to prevent potential ground loops that can exist in instances where the IRU and receiver are not sharing the same power source (See Figure 1.1). The 4-20 mA circuit can also be wired as a standard current sourcing 4-20 mA loop simply by powering the circuit from the same power source used by the main IRU sensor circuit (See Figure 1.2).

RST-3001/2 Programming Module Wiring

All IRU sensors (excluding the IRU-6429S and IRU-9429S) are fully programmable using an RST-3002 programming module, which acts as an interface between the sensor and a personal computer. The RST-3002 is both 32- and 64-bit Windows compatible.

The RST-3002 is connected in series between the sensor and its power source using the two 2-pin Phoenix connectors on the module (See Figure 1.3). 15-28 VDC from the power source is connected to one 2-pin connector, while the VDC + and DC Ground of the sensor is connected to the module through the second 2-pin connector. When power is applied, the red LED between the Phoenix connectors on the RST should illuminate and the sensor should start audibly “ticking”. The operating parameters of the sensor can then be adjusted using the Windows-based utility software.

NOTE: The utility software can be downloaded at: https://www.apgsensors.com/resources/product-resources/software-downloads.

Excitation Wiring for IRU-XXX9 Sensors

0-2.5 / 0-5 VDC IRU sensors include an +5 VDC Excitation input. (See Figure 1.4) If voltage is not applied at the Excitation input, the sensor will not communicate for programming, nor will it provide the 0-2.5 / 0-5 VDC output.

In essence, this allows for a small VDC supply, such as +5 VDC from a datalogger, to “wake” the sensor for output recording, and subsequently put the sensor back to “sleep.”

IRU-200X Clock Synchronization Wiring

IRU-2002, IRU-2003, IRU-2004-C, and IRU-2005-C sensors are equipped with a clock synchronization to prevent cross-talk between sensors located in close proximity. When the clock sync terminals of two or more sensors are connected (See Figure 1.5), the output signals will synchronize. The sensors must share a common ground in order for the clock synchronization feature to function.

NOTE: If sensors with synced clocks are facing each other with no object in between them, each will receive the other’s pulses as its own, resulting in both sensors showing a measurement of half the distance between the sensors. This measurement should be interpreted as “No Object Present”.

INSTALLATION AND REMOVAL PROCEDURES

INSTALLATION AND REMOVAL PROCEDURES AND NOTES

Tools Needed

Tools are necessary only for the screws used to install the surface mount IRU-200X, and to access the terminal strips inside IRU-2002 and IRU-2003 sensors. All other models can be mounted via NPT threads on the sensors.
If you are using a stand pipe to mount your IRU, you will probably need tools to install the stand pipe.

NOTE: Terminal strips for IRU-2002 and IRU-2003 sensors are internal to the sensor and must be connected before sensors are mounted.

Potentiometers for setting or adjusting Trip Distance (IRU-2002 only) and Sensitivity (IRU-2002 and IRU-2003) are located inside the sensor housing along with terminal strips (See Figures 2.1 and 2.2). Both settings can also be controlled via the I2000SWR software (See Figure 3.3).

Installation Notes

Mount your IRU sensor so that it has a clear, perpendicular sound path to the surface being monitored. Your sensor should be mounted away from tank or vessel walls and inlets. (See Figure 2.3)
The sound path should be free from obstructions and as open as possible for the 9° off axis beam pattern.

If you are using a stand pipe, please see our guide to stand pipes on our website: http://www.apgsensors.com/about-us/blog/how-to-install-a-stand-pipe.

NOTE: Do not mount the sensor where the beam will intersect objects such as fill streams, pipes, ladder rungs, wall seams, or corrugated tank walls.

Mounting Instructions

Mounting your IRU is easy if you follow a few simple steps:
- For IRU-200X sensors, use the necessary screws or bolts (not provided by APG) to mount the sensor.

For all other IRU models:
- Never over-tighten the sensor.
- Always screw in your sensor by hand to avoid cross-threading. Thread failure can be a problem if you damage threads by over-tightening them or by crossing threads.

IMPORTANT

Do not over tighten! The sensor should be threaded in only hand tight.

Electrical Installation

Check the pinout table on your IRU against your order
Check that your electrical & control system wiring matches the pinout table on your IRU.
For sensors with connectors, make the connection. For instruments with pigtails, run the cable to a junction box in a suitable location to connect to your system.

For IRU-2002 and IRU-2003 sensors, system wiring must be connected to internal terminal strips prior to physical installation. (See Figures 2.1 and 2.2)

NOTE

Please see wiring diagrams in Chapter 1 for RST Module Programming Wiring and other special wiring configurations.

Software Installation

Download the RST-3002 software zipfile from https://www.apgsensors.com/resources/productresources/software-downloads/.
Open the zip file.

Choose “Install” from the options at the top of the zip file window.
The installation process will prompt you as needed to complete the installation.
The software will create I2000SWR.exe which will run from a folder in your start menu titled “APG/I2000SWR”.

IMPORTANT

RST-3002 is compatible with computers running 32- and 64-bit Windows systems.

Removal Instructions

Ensure that power to the sensor is off
Disconnect cable to sensor.
Remove the sensor and store it in a dry place, at a temperature between -40° F and 180° F.

If the sensor was installed in a hazardous location, ensure that the cable will not energize while the sensor is disconnected.

DANGER: Do not disconnect equipment installed in hazardous locations unless power has been switched off or area is known to be non-hazardous.

SET UP AND OPERATION

User Interface

IRU sensors use one of two methods for user interface: RS-232 serial communications (IRU-6429S and IRU-9429S) or I2000SWR, the Windows-based utility software (all other models).

RS-232 Serial Communication

Sensors with the built-in RS-232 communications will accept one ASCII command (SEND), and return distance and temperature values in ASCII. When the sensor receives the SEND command (all capital letters), the sensor will transmit the distance in feet, followed by a comma, and then the temperature in degrees Celsius, followed by a carriage return and line feed. The distance will be five characters (e.g. 05.25) and the temperature will have a + or – followed by one or two characters (e.g .+22).

IMPORTANT

The sensor will return ASCII characters, not numeric values.

NOTE: If your sensor is turned off between readings, you must allow time for the sensor to initialize and process readings through filtering parameters before polling for output readings with a SEND command. Depending your filter settings, this can take between 3 and 30 seconds, or longer.

Windows-based Utility Software: I2000SWR

I2000SWR software user interface is one screen with three primary areas (See Figure 3.1). The primary portion of the screen is two columns of Sensor Parameters. The Sensor Readings and Communication Status area is below the Sensor Parameters, in two uneven columns. Finally, the Control Buttons area is located across the bottom of the screen.

Only the fields in the Sensor Parameters are editable by the user. All of the fields in the Sensor Readings and Communication Status area are display only.

The top and middle Communication Status boxes in the right column show the status of communication between the I2000SWR software and the RST-3002, and between the I2000SWR software and the sensor (See Figure 3.2).

When the I2000SWR software is started it will attempt to establish communications with your IRU sensor via the RST-3002 module. The Send button will grey-out and the Sensor Communication Status will display “Receiving all data!!” During this initial communication, the software will determine the model number of your sensor (IRU-XXXX), configure the available parameters accordingly, and load the current parameter values from the sensor.

If the sensor model in the upper left-hand corner of the window does not change from the default (IRU-2003), then a communication error has occurred. Check all wiring to ensure proper connections have been made (See Figure 1.3). Then close (Exit) the software and open it again. Changes to parameters are written to the sensor by clicking on the Send button. During the writing process, the Sensor Communication Status will display “Sending all data!!” The message will the change to “Communication Error!!!” and the parameter fields will briefly change to green. The fields will then blank to white and the Sensor Communication Status will display “Receiving all data!!” At this point the parameter fields will turn greyish-blue and be populated with the new values read from the sensor.

The “Communication Error!!!” message in this process is a result of the brief time needed for the sensor to switch from receiving the new parameters to sending all the parameters back to the software. As long as your changes are reflected in the final read of the sensor data, there has not been an actual communication error.

IRU Sensor Parameters

Units is used to select the units of measurement for parameter display. The units will also determine the resolution of the display and the outputs. The resolution is: feet 0.01, inches 0.1, and millimeters 1. When a new unit of measure is selected, the software will automatically communicate with the sensor and update appropriate parameters.

Blanking sets the blanking distance, which is the zone from the Zero Point of the sensor to the point from which the first echo will be accepted. While blanking distance can be used to ignore unwanted targets—such as welds, seams, pipe fittings, or gaskets—between the sensor and the closest acceptable target level, such objects generally create additional reflections and echoes, which are hard to filter out. More often, blanking distance is used for a sensor installed in a stand pipe. Because of the physical properties of an ultrasonic sensor, objects cannot be detected closer than approximately 1 foot from the face of most transducers (4 inches for IRU-5XXX, and 6 inches for IRU- 942X). However, this distance varies according to how much energy is being transmitted (Pulses) and the installation.

IMPORTANT

Blanking is always measured from the Zero Point of the sensor. See Figures 3.4 – 3.6.

Sensitivity sets the level of gain that is applied to the echo. When operating in AutoSense, Hard- Target, or Soft-Target (see Gain Control), Sensitivity sets an upper limit for the amplification that can be applied to the echo. If operating in Manual, this parameter sets the gain. When using manual gain control, set Sensitivity to the minimum value that will allow the target to be reliably tracked through the full range of expected environmental conditions.

For IRU-2002 sensors, Sensitivity/Trip Point Control is used to select between potentiometer or software control of Sensitivity and Relay Trip Point. (See Figure 2.1) For IRU-2003 sensors, Sensitivity/Trip Point Control is used to select between potentiometer or software control of Sensitivity. (See Figure 2.2)

Pulses sets the maximum number of pulses the sensor can transmit when operating in AutoSense, Hard-Target, or Soft-Target (see Gain Control), or sets the number of pulses when operating in Manual. The more pulses that are sent in a burst, the stronger the returning echo.
When operating in Manual, increase the strength of the transmission by increasing Pulses for detecting soft targets in damping environments. In acoustically active environments or small enclosed areas, decrease Pulses to reduce multiple echoes.

Gain Control selects the control mode for the sensor’s gain settings (Sensitivity and Pulses). In AutoSense, the sensor automatically adjusts the sensitivity and pulses for the best quality return signal. Manual, Hard Target, and Soft Target are user controlled scenarios. In Manual, the user is in full control of Sensitivity and Pulses. For Hard and Soft Target, the user sets maximum Sensitivity and Pulses, but the overall gain is either ramped up slowly (Hard Target) or quickly (Soft Target) by the sensor.

Average sets the number of qualified received signals to average for the displayed reading. Qualified received signals are placed in a first-in, first-out buffer, the contents of which are averaged for the displayed output. The larger the number of qualified received signals being averaged, the smoother the output reading will be, and the slower the reading will be to react to quickly changing targets.

Window determines the physical range of qualified received signals, based on the current reading.
Signals beyond the +/- Window range of the current reading will not qualify unless the average moves. Signals outside the extents of the Window are written to the Out of Range Samples buffer.

Out of Range Samples sets the number of consecutive samples outside the Window necessary to automatically adjust the current reading and move the Window.

Sample Rate is the number of samples taken by the sensor every second.
While higher sample rates allow for quicker sensor response times to changing levels, lower sample rates reduce the likelihood of echo-based false positives. Also, lower sample rates result in longer sensor life.

Multiplier is used to calibrate the sensor for variations in the speed of sound due to variations in atmospheres. The default of 1.000 is used for most applications. See the Calibration section of Chapter 4.

Offset is used to change the Zero Point of the sensor. This is not the zero output (4 mA, 0 V, etc.) point of the sensor. The Zero Point of the sensor is the point from which the calculated distance is measured. When the Offset is set to 0, the Zero Point of the sensor is at the face of the transducer (See Figure 3.4). A positive setting will move the Zero Point forward, in front of the sensor face (See Figure 3.5). Setting the Offset to a negative number will move the Zero Point backward, behind the sensor face (See Figure 3.6).

In all cases, Blanking is measured from the end of Offset, and the effective measurement zone of the sensor begins at the forward end of Blanking. If Offset is more negative than Blanking is positive, the net difference will be a loss in sensor maximum range (See Figure 3.6).

Temperature Compensation activates or deactivates the IRU’s internal temperature compensation circuit. The speed of sound changes with changes in temperature, therefore changes in temperature can affect distance measurements. These effects can be minimized by activating temperature compensation.

NOTE: If the internal temperature compensation is enabled and the sensor is exposed to direct sun light, the radiant heat can warm the sensor housing above the ambient temperature, which can affect the internal temperature sensor and cause overcompensation.

Maximum Distance sets the maximum acceptable signal range for the sensor, measured from the Zero Point.
Signals beyond the Maximum Distance are ignored. Under Loss of Echo conditions, the software distance reading will display the Maximum Distance.

View Noise Level displays the number of echoes being picked up by the sensor.
The presence of more than 30 echoes often indicates a noise source (acoustical or electrical) that could hamper sensor operation. Reducing the Sensitivity and Pulses may help cut down the influence of noise.

Set Noise Threshold sets an activation level for the sensor’s noise filter. When the noise level exceeds the threshold, the filter activates a steady reading on the sensor until the noise level returns below the threshold. If periodic, short-term noise sources are known to be operating near the sensor, this threshold can be set to prevent false readings during noise-source activities.

4 mA Set Point sets the distance at which the output is 4 mA. This distance is measured from the Zero Point. See Figures 3.3 and 3.4.

20 mA Set Point sets the distance at which the output is 20 mA. This distance is measured from the Zero Point. See Figures 3.7 and 3.8.
For Distance configuration (i.e., greater mA output for target surface further from sensor), set the 4 mA Set Point to be less than the 20 mA Set Point. See Figure 3.7.
For Fill configuration (i.e., greater mA output for target surface closer to sensor), set the 4 mA Set Point to be greater than the 20 mA Set Point. See Figure 3.7.

0 VDC Set Point sets the distance at which the output is 0 VDC. This is measured from the Zero Point. (See Figures 3.9 and 3.10)

5 VDC Set Point and 2.5 VDC Set Point set the distance at which the output is high voltage (2.5 or 5 VDC). This is measured from the Zero Point (See Figures 3.9 and 3.10). Use the Max Voltage parameter to select the high voltage output.
For Distance configuration (i.e., greater VDC output for target surface further from sensor), set the 0 VDC Set Point to be less than the 2.5/5 VDC Set Point. (See Figure 3.9)
For Fill configuration (i.e., greater VDC output for target surface closer to sensor), set the 0 VDC Set Point to be greater than the 2.5/5 VDC Set Point. (See Figure 3.9)

Max Voltage selects the maximum DC voltage sourced on the analog output. (See Figure 3.10)

5 Volt Calibrate and 2.5 Volt Calibrate fine tune the maximum DC voltage sourced on the analog output.

4 mA Calibrate fine tunes the minimum current sourced on the analog output. (See Figure 3.8)

20 mA Calibrate fine tunes the maximum current sourced on the analog output. (See Figure 3.8)

Relay and NPN Trip Output Configuration

Along with, or instead of, an analog output, some IRU sensors have relay (IRU-2002) or NPN Trip (IRU-2004, IRU-XXX5) outputs. The relay or NPN can be configured to turn on or off based on the measurement of the sensor. (See Figure 3.11)

Trip Distance sets the distance to the trip position closest to the sensor face.

Trip Window sets the distance from the first trip position to the trip position farthest from the sensor face.

Near activates the output whenever the target surface is closer than the Trip Distance setting.

Exclusive activates the output whenever the target surface is closer than the Trip Distance setting OR beyond the Trip Distance + Trip Window setting.

Hysteresis Near activates the output whenever the target surface moves closer than the Trip Distance setting. The output remains activated until the target surface moves beyond the Trip Distance + Trip Window setting. The output remains off until the target surface moves closer than the Trip Distance setting again.

Far activates the output whenever the target surface is beyond the Trip Distance setting.

Inclusive activates the output whenever the target surface is beyond the Trip Distance setting AND closer the Trip Distance + Trip Window setting..

Hysteresis Far activates the output whenever the target surface moves beyond the Trip Distance + Trip Window setting. The output remains activated until the target surface moves closer than the Trip Distance setting. The output remains off until the target surface moves beyond the Trip Distance + Trip Window setting again.

Sensor Readings and Communication Status

Below the Sensor Parameters and Output Configuration is the Sensor Readings and Communication Status area. On the left side are three sensor reading displays: Distance, Temperature, and Analog Output (current or voltage). On the right side are three or four communication status displays: USB status, Trip 1, Trip 2, or Relay Status (depending on sensor model), Sensor Communication Status, and Signal Strength Status. (See Figure 3.13)

Distance displays the current output of the sensor in the units selected in the Units parameter above.

Temperature displays the current temperature of the thermal device in the IRU sensor body.

Analog Output displays the current analog output (all models except IRU-2002 and IRU-2004) of the sensor.

USB Status displays the status of the USB connection between the I2000SWR software and the RST- 3002 as detected when the software initiated.

Trip Status displays the status of the relay (IRU-2002), NPN Trip (IRU-2004), or NPN Trips (IRU-XXX5).

Sensor Communication Status displays the current status of communication between the I2000SWR and the IRU sensor. Typically this box is blank. The three messages—”Receiving all data!!”, “Sending all data!!”, and “Communication Error!!!”—only display while their respective events are happening.

Signal Strength Status displays the strength of the signal being received by the sensor. 0 represents the highest quality signal, and 7 represents the lowest quality. For some sensor models, the Signal Strength Status may show “Default” if the sensor is not fully communicating with the I2000SWR software. Other models only display “Default,” and never show the 0-7 range.

Control Buttons

Below the Sensor Readings and Communication Status area are four Control Buttons. On the left side are three sensor communication buttons: Send, Receive, and Reset. In the middle are a dropdown box and check box for selecting the communication channels. On the right side is the Exit button. (See Figure 3.14)

Send sends all the user-entered values for sensor parameters to the sensor. After sending the parameters to the sensor, the software will automatically poll the sensor to receive back all parameters. The Sensor Communication Status display will show the progression of the writing and reading of sensor parameters.

Receive polls the IRU sensor to read all the sensor parameters into the software. The Sensor Communication Status display will show the progression of the reading of sensor parameters.

Reset returns all sensor parameters to their factory settings. After resetting the parameters on the sensor, the software will automatically poll the sensor to receive back all parameters The Sensor Communication Status display will show the progression of the resetting and reading of the sensor parameters.

Com Channel selects the computer’s communication port used for RS-232 serial communication between the I2000SWR software and the IRU sensor. If you are using an RST-3002 via USB you do not need to use this dropdown box.

The USB checkbox directs the I2000SWR software to use communicate with the IRU sensor via USB and an RST module. If the box is unchecked, the software will use RS-232 via the selected com port in the Com Channel dropdown box.

Exit closes the I2000SWR software. Sensor parameters that have been successfully written to the sensor will be stored in non-volatile memory on the IRU.

Saving and Loading Parameter Files

In the File Menu are options for saving and loading parameters in text (.txt) files. Save Parameters will write the current values for all parameters in the I2000SWR software to a .txt file. Load Parameters will load all the parameters in a .txt file into the I2000SWR software. The parameters will not be written to the IRU until the Send button is clicked. Similarly, to ensure that the current parameters in the IRU are written to a file, Receive must be clicked before choosing File>Save Parameters.

Saving and loading parameters is especially helpful for setting up several identical sensors in identical settings. Once the parameters for the first sensor are configured appropriately, the parameters can be saved in a .txt file and subsequently loaded into the remaining sensors.

MAINTENANCE

General Care

Your IRU ultrasonic sensor is very low maintenance and will need little care as long as it was installed correctly. However, in general, you should:

Avoid applications for which the sensor was not designed, such as extreme temperatures, contact with incompatible corrosive chemicals, or other damaging environments.
Inspect the threads whenever you remove the sensor from duty or change its location (for sensors with NPT threads).

Trouble Shooting

Should you have problems with your IRU, here are some troubleshooting steps.

Check the Signal Strength Status (See Figure 3.9 and explanation). If the signal strength is low, alternately increase Pulses and Sensitivity until the signal strength improves.
Ensure Temperature Compensation is turned on.
Set Gain Control to AutoSense.
Ensure that Blanking (page 18 )is accurately set to account for any unwanted targets between the sensor and the closest acceptable target.
Ensure that the Noise Threshold is greater than the Noise Level.
Ensure that the settings for Average and Window allow for anticipated target surface movement without adversely effecting the output reading.

Calibration

This procedure uses targets at known distances to calibrate the sensor’s accuracy. A wall or other large, flat object is recommended for the long range target.

Point the sensor at a target at a known distance near the maximum range of the sensor (See Figure 4.1).
Adjust the Multiplier until the distance reading on the sensor matches the actual measured distance to the target.
Point the sensor at a target near the minimum measurement range plus any Blanking distance (See Figure 4.2).
Adjust the Offset value until the distance reading on the sensor matches the actual measured distance to the target.
Repeat previous two steps until no further adjustment is required.

NOTE: The Reset button in the I2000SWR software will reset the IRU to factory default settings (See Figure 3.14).

Repair and Returns

Should your IRU ultrasonic sensor require service, please contact the factory via phone, email, or online chat. We will issue you a Return Material Authorization (RMA) number with instructions.

Phone: 888-525-7300
Email: sales@apgsensors.com
Online chat at www.apgsensors.com

Please have your IRU sensor’s part number and serial number available. See Warranty and Warranty Restrictions for more information.

HAZARDOUS LOCATION DRAWING AND CERTIFICATION

Hazardous Location Drawing

Installation In Class I Division 2 Groups C and D Class | Zone 2 A Fx nA |IR

WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD – Clean only with a damp cloth

Install in accordance with Section 18 of the CEC or Article 500 of the NEC.
CSA listed or NRTL/UL listed conduit seal at location A & B.
The cable is potted into the sensor and runs continuously from the sensor through the Hazardous area and into the Non-Hazardous area.
Electrical equipment connected to associated apparatus should not generate more than 250 V rms.
Tampering or replacement with non-factory components may adversely affect the safe use of the system.
WARNING: DO NOT DISCONNECT WHILE CIRCUIT IS ALIVE UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS.

Certificate of Compliance

CSA Certificate of Compliance

CONTACT

Automation Products Group, Inc.

Tel: 1 888-525-7300 or 1 435-753-7300
e-mail: sales@apgsensors.com
www.apgsensors.com

Automation Products Group, Inc.

1025 W. 1700 N. Logan, UT 84321

Documents / Resources

APG IRU Series Ultrasonic Sensors [pdf] User Manual
IRU Series Ultrasonic Sensors, IRU Series, Ultrasonic Sensors, Sensors

References

User Manual

APG IRU Series Ultrasonic Sensors

Product Usage Instructions

FAQ

MODELS

INTRODUCTION

WARRANTY

SPECIFICATIONS AND OPTIONS

INSTALLATION AND REMOVAL PROCEDURES

SET UP AND OPERATION

MAINTENANCE

HAZARDOUS LOCATION DRAWING AND CERTIFICATION

Certificate of Compliance

CONTACT

Documents / Resources

References

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