BA USi Safety - EN

Innovative by tradition.
Ultrasonic industrial sensor USi® safety

EN | Operating instructions Version 1
1006504 USi® safety *
* in addition sensor 1005264

or sensor 1006878
Mayser GmbH & Co. KG

Örlinger Straße 1–3
89073 Ulm
GERMANY
Phone: +49 731 2061-0
Fax: +49 731 2061-222
E-mail: info.ulm@mayser.com
Original instructions Internet: www.mayser.com
Content
Contents
About this manual..................................................................................................................................................................5
Intended use.............................................................................................................................................................................7
Limits........................................................................................................................................................................................7
Exclusions................................................................................................................................................................................7
Safety instructions...................................................................................................................................................................8
Parts supplied...........................................................................................................................................................................9
Transport and storage............................................................................................................................................................9
Packaging and transport.....................................................................................................................................................9
Storage.....................................................................................................................................................................................9
Product overview...................................................................................................................................................................10
Sensor (ultrasonic transducer)........................................................................................................................................ 10
Evaluation unit.................................................................................................................................................................... 10
LED indicators...................................................................................................................................................................... 11
Connections........................................................................................................................................................................ 11
Unit cable with M12 socket............................................................................................................................................. 12
Temperature sensor........................................................................................................................................................... 13
Sonic Lobe............................................................................................................................................................................ 13
Operation.................................................................................................................................................................................15
Operating mode 1 range.................................................................................................................................................. 15
Operating mode 2 ranges................................................................................................................................................ 16
Expansion “reference axis only”...................................................................................................................................... 16
Examples of use.................................................................................................................................................................. 17
Protection field design...................................................................................................................................................... 17
Consider the temperature................................................................................................................................... 18
Calculating the protection field.......................................................................................................................... 19
Minimum distance with stationary hazard protection................................................................................. 20
Minimum distance with mobile hazard protection....................................................................................... 22
Determining the validation................................................................................................................................. 23
Installation situation of the sensors............................................................................................................................... 25
Flush installation.................................................................................................................................................... 25
Installation with funnel........................................................................................................................................ 25
Installation with reference object...................................................................................................................... 25
Installation position of the temperature sensor......................................................................................................... 26
Advantages and disadvantages......................................................................................................................... 26
Installation...............................................................................................................................................................................27
Mounting the sensor (ultrasonic transducer).............................................................................................................. 27
Key for safe function............................................................................................................................................. 27
Alternative 1: use your own mounts................................................................................................................. 29
Alternative 2: M30 housing................................................................................................................................ 30
Copyright
The reproduction, distribution and utilization of this document as well as the communication of its contents with-
out express authorization are prohibited. Offenders will be held liable for the payment of damages. All rights re-
served in the event of the grant of a patent, utility model or design.
© Mayser Ulm 2019
Page 2/107 Operating instructions USi safety 211019 v2.00

Content
Mounting the temperature sensor................................................................................................................................ 31

Mounting the evaluation unit......................................................................................................................................... 31
Wiring the unit cable......................................................................................................................................................... 32
Safe wiring of OSSDs............................................................................................................................................. 33
Commissioning.......................................................................................................................................................................34
First commissioning........................................................................................................................................................... 35
Log in..................................................................................................................................................................................... 36
For demonstration purposes........................................................................................................................................... 36
Approval............................................................................................................................................................................... 37
Protection field testing...................................................................................................................................................... 39
Testing................................................................................................................................................................................... 40
Recording the protocol..................................................................................................................................................... 41
System restart...................................................................................................................................................................... 42
Automatic reset...................................................................................................................................................... 42
Correlations......................................................................................................................................................................... 43
Adjust settings........................................................................................................................................................................45
Overview of the Standard tab......................................................................................................................................... 46
Logon/logoff sensor 2....................................................................................................................................................... 47
Specifying the protection field range............................................................................................................................ 48
Dividing an area.................................................................................................................................................................. 49
Defining signal outputs OUT........................................................................................................................................... 50
Cancelling the power-on start interlock....................................................................................................................... 51
Specifying the restart delay............................................................................................................................................. 52
Saving settings.................................................................................................................................................................... 53
Loading settings................................................................................................................................................................. 54
Changing the password................................................................................................................................................... 55
Reset parameters............................................................................................................................................................... 57
Carrying out a RESET......................................................................................................................................................... 58
Read fault status................................................................................................................................................................. 59
Send info to Mayser........................................................................................................................................................... 60
Logging out USi safety...................................................................................................................................................... 61
Automatic log-out................................................................................................................................................. 61
Changing the language.................................................................................................................................................... 62
Display Inch and Fahrenheit............................................................................................................................................ 63
Expanded settings for experts...........................................................................................................................................64
Activate expert mode........................................................................................................................................................ 64
Overview of the Expert mode tab.................................................................................................................................. 65
Typical procedure............................................................................................................................................................... 65
Echo amplification............................................................................................................................................................. 67
Sensitivity............................................................................................................................................................................. 68
Multiple scan....................................................................................................................................................................... 69
Power-up delay................................................................................................................................................................... 70
Near field up to................................................................................................................................................................... 71
Echo broadening starting at............................................................................................................................................ 72
Hysteresis............................................................................................................................................................................. 73
Determining the TVG........................................................................................................................................................ 74
Select transmission intensity........................................................................................................................................... 75
Setting temperature compensation.............................................................................................................................. 77
Setting reciprocal interference suppression................................................................................................................ 78
211019 v2.00 Operating Instructions USi safety Page 3/107

Content
Checking the detection field..............................................................................................................................................79

Overview of the Diagnosis tab........................................................................................................................................ 80
Teach in: Teaching the environment in again.............................................................................................................. 81
Generating oscillograms................................................................................................................................................... 81
Preselection for the oscillogram......................................................................................................................... 82
Interpreting oscillograms................................................................................................................................................. 83
Troubleshooting and remedies.........................................................................................................................................85
Replacement parts............................................................................................................................................................. 88
Accessories...............................................................................................................................................................................89
Maintenance and cleaning.................................................................................................................................................90
Maintenance....................................................................................................................................................................... 90
Cleaning............................................................................................................................................................................... 90
Decommissioning..................................................................................................................................................................91
Disposal....................................................................................................................................................................................91
Conformity..............................................................................................................................................................................92
EC design test...................................................................................................................................................................... 92
Factory settings......................................................................................................................................................................93
Technical data.........................................................................................................................................................................94
Flow chart................................................................................................................................................................................96
Start....................................................................................................................................................................................... 96
Detection.............................................................................................................................................................................. 97
Parameterising.................................................................................................................................................................... 98
Glossary....................................................................................................................................................................................99

About these operating instructions
About this manual
This manual is an integral part of the product.

Mayser will assume no liability and provide no guarantee whatsoever for damages
and consequential damages resulting from failure to comply with the manual.
ÄÄ Read the manual carefully before use.
ÄÄ Keep the manual for the complete service life of the product.
ÄÄ Pass the manual on to every subsequent owner or user of the product.
ÄÄ Add any supplement received from the manufacturer to the manual.
Validity This manual is valid only for the product specified on the title page.
Target group The target group of these operating instructions are manufacturers and operators of
machines who are familiar with the risk assessment according to ISO 12100 as well
as the installation and commissioning of protective devices.
Glossary Technical terminology is alphabetically listed and explained at the end of the manual.
Symbols used Symbol Meaning

ÄÄ ... Action with one or more steps whose order is not rele-
vant.
1. ... Action with several steps whose order is relevant.
• ... Bullets first level

-- ... Bullets second level
(see Section Installation) Cross-reference

About these operating instructions
Danger symbols and Symbol Meaning

information 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 minor or moderate

injuries
Information on easier and safer working practices

Intended use
Intended use
The safe ultrasonic industrial sensor USi safety 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:
•• Reflex switch
•• Reflex barrier
The integrated output signal switching devices (OSSD) transmits the evaluated safety
signals directly to the machine control.
There are two additional configurable outputs (OUT) available.
The product complies with ISO 13849-1:2015 Category 3 PL d. So that the

safety classification is retained, the downstream control must be of the same or a
higher category.
Limits
•• 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 cannot
be reliably detected.
•• Strong fluctuations in temperature within very short periods of time cannot
counter balance the temperature compensation.
These constraints can be reduced with optimised sensor assembly or suitable param-
eterisation though.
Exclusions
•• The use of the product in potentially explosive environments (ATEX) is not possi-
ble. The product is not authorised for use in these areas.

Safety instructions
Safety instructions
ÄÄ Do not open sensors (ultrasonic transducer)

Never open, manipulate or alter the sensors.
ÄÄ Do not squeeze the sensors

Avoid applying increased mechanical loads to the enclosure and the active sur-
face of the sensor (ultrasonic transducer).
ÄÄ Check supply voltage

Check supply voltage. It must correspond with the connecting voltage US on the
type plate.
ÄÄ Observe degree of protection

The evaluation unit only has a degree of protection of IP65 with carefully screwed
on screw plug and carefully fitted lid.
ÄÄ Protect from sunlight

In the case of surface installation, ensure that the evaluation unit is protected
from direct sunlight.
ÄÄ Do not alter special cable

The special cable on the sensor (ultrasonic transducer) has a fixed length. Never
shorten, lengthen or alter the special cable.
ÄÄ Observe PIN assignment

Observe the PIN assignment when connecting the supply voltage.
ÄÄ Do not overload evaluation unit

Ensure that the specified switching current is not exceeded.
ÄÄ Replacing wear parts

Exchange wear parts like O-rings and sensors in time.
ÄÄ In the event of a fault, take out of operation

In the event of malfunctions and visible damage, take the control unit out of op-
eration.

Parts supplied
Parts supplied
1× Evaluation unit
Enclosure with electronics module.
1× Sensor (ultrasonic transducer)
1× Operating instructions
1× Declaration of conformity
1× USB stick (parameterisation software)
ÄÄ Upon receipt of the parts supplied, check immediately for completeness and
good condition.
Required accessories:
1× Unit cable M12x8 / USi (optional)
Tip: You can find recommended accessories in chapter Accessories.
Transport and storage
Packaging and transport

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.
The USB stick (parameterisation software) is enclosed loosely.
Storage
ÄÄ Store the individual parts in the original packaging in a dry place.
ÄÄ Observe the storage temperatures given in the technical specifications.

Product overview
Product overview
Sensor (ultrasonic transducer)

The special cable between the sensor (ultrasonic transducer) and the M8 plug has a
fixed length of 1.5 m or 3.0 m and may not be lengthened or shortened.
1 Sensor (ultrasonic transducer) 3 M8 plug

2 Active surface 4 Shielded cable
Evaluation unit
5 Fastening point (M4) 8 M8 socket X2: RS485, TEMP

6 M8 socket U2: Sensor 2 9 M12 plug X1: Unit cable
7 M8 socket U1: Sensor 1 10 Screw plug: Mini USB

Product overview
LED indicators
•• Green LED “Power“:
supply voltage connected
•• Yellow LED “Warning“:
critical operating state
•• Red LED “Fault“:
error; OSSD are OFF
•• Green LED “OSSD“:

safe output is ON
•• Red LED “OSSD“:
safe output is OUT
•• Yellow LED “OUT“:

signal output is activated
Connections
View with covers.
View without covers: 8 M8 socket X2: RS485, TEMP

6 M8 socket U2: Sensor 2 9 M12 plug X1: Unit cable
7 M8 socket U1: Sensor 1 10 USB socket: Mini-B

Product overview
Connection Type Explanation

Mini USB 2.0 for parameter assignment via soft-
ware
X1 M12, 8-poled for unit cable
X2 M8, 6-poled RS485 interface, temperature sensor
U1 M8, 3-poled Sensor 1 (ultrasonic transducer 1)
U2 M8, 3-poled Sensor 2 (ultrasonic transducer 2)
Plug X1 Signal PIN Circular connector

Supply voltage +US 2
-US 7
Safe output 1.1 OSSD 1.1 1
Safe output 2.2 OSSD 2.2 5 M12
Signal output 1 OUT 1 6
Signal output 2 OUT 2 8
Unit cable with M12 socket

Cable for connection with downstream control.
The LifYCY type device cable must be 8-pole (at least 0.25 mm2 per core), shielded
and equipped with an M12 socket.
Maximum device cable length: 30 m.
A device cable with a cable length of 2 m available as an accessory.
Signal PIN Lead colour

Supply voltage +US 2 BN Brown
-US 7 BU Blue
Safe output 1.1 OSSD 1.1 1 WH White
Safe output 1.2 OSSD 1.2 3 GN Green
Safe output 2.1 OSSD 2.1 4 YW Yellow
Safe output 2.2 OSSD 2.2 5 GY Grey
Signal output 1 OUT 1 6 PK Pink
Signal output 2 OUT 2 8 RD Red

Product overview
Temperature sensor
The temperature sensor (optional; part no. 1006566) is equipped with an M8 plug
and a cable with a length of 1.5 m.
1 Temperature sensor 3 M8 socket

2 Mounting tab 4 Cable
Sonic Lobe
The following representations refer to the product in delivery condition. Measure-
ment object: steel rod with Ø 10 mm. If parameters have been changed or if a differ-
ent measurement object is used, the representations will change accordingly.
Sonic lobe from the

narrow side and the
broad side
Reference axis

Product overview
Opening angle (-6 dB)

narrow side
Reference axis
Opening angle (-6 dB)

broad side
Reference axis
Sonic lobe spatially

Function
Operation
USi safety is a contactless protective device (CPD) and complies with ISO 13849-
1:2015 category 3 PL d.
The safe ultrasonic industrial sensor USi safety uses the connected sensors (ultrasonic
transducers) to both transmit and receive sound in the medium air. With a complex
measurement method, objects as well as persons and parts of persons are reliably
detected.
If the switching points SP1 and SP2 are defined and the protection field test was suc-
cessful, then USi safety starts detecting in the predefined operating mode. The two
possible operating modes are:
•• Operating mode 1 range
•• Operating mode 2 ranges
Operating mode 1 range

Operating mode 1 range is the preset standard operating mode.
SP1: 200 cm SP2: 200 cm
If SP1 = SP2, then there is no upstream warning field. From the minimum switching
distance to switching point SP2 only one range extends as a detection field: the pro-
tection field.
If an object enters the detection field, the safe outputs OSSD go into the OFF state
(red LEDs are lit), the signal output OUT is activated (yellow LED is lit).

Function
Operating mode 2 ranges

If switch point SP2 selection is larger than switch point SP1, the USi safety automati-
cally changes to operating mode 2 ranges.
SP1: > 15 cm SP2: > (SP1 + 1 cm)
If SP1 < SP2, then the detection field is divided into 2 ranges: protection field and
warning field. The detection field (red) close to the sensor extends from the mini-
mum switching distance to switching point SP1 and defines the protection field.
The detection field (yellow) far from the sensor extends from the minimum switching
distance to switching point SP2 and defines the warning field. The safe outputs
OSSD are assigned to the protection field, the signal output OUT to the warning field.
If an object enters the warning field (yellow), the signal output OUT is activated (yel-
low LED OUT lights up). If an object enters the protection field (red), the safe outputs
OSSD go into the OFF state (red LEDs are lit), the signal output stays activated (yellow
LED is lit).
Expansion “reference axis only”

In both operating modes, expanding the protection field range is possible by select-
ing the option “expanded (reference axis only)”. The protection field can now be pa-
rameterised to a width of 2.5 m. Prerequisite: The anticipated objects always enter
the detection field in the immediate vicinity of the reference axis (see Chapter Speci-
fying protection field range).

Function
Examples of use
Object detection
1. Simplest function: Is an object locat- 1. Operating mode 1 range.
ed in the free detection field?
2. Presence / absence monitoring: Does 2. Operating mode 1 range.

the taught-in environment change?
Distance detection
3. Distance check: When is a defined 3. Operating mode 1 range and specifi-
distance not reached? cation of the switch point SP1 = SP2.
4. Two-zone observation: Did an object 4. Operating mode 2 ranges and speci-

enter the warning field? fication of the switch points SP1 and
With further approach: Did an object SP2.
enter the protection field?
Obstacle detection
5. Path check: Is the path taken unob- 5. Operating mode 1 range.
structed?
6. Distance check: When is a defined 6. Operating mode 2 ranges and speci-

distance to the obstacle fall so far fication of the switch points SP1 and
short (SP1) that action must be tak- SP2.
en?
Protection field design

Whether it is object detection, distance detection or obstacle detection, you do not
reach the highest performance with random adjustment of various parameters of
the USi safety. More expedient is a systematic approach that starts with meaningful
protection field design, uses strategy for parameter alignment and ends with the de-
termination of how the protection function is to be validated.
This chapter illustrates the most important factors that are necessary for an effective
protection field design.

Function
Consider the temperature
USi safety is designed exclusively for the medium air. The ultrasound technology used
already indicates that sound is used for measurements. The measurement methods
thus has one constant: the speed of sound.
The speed of sound – along with the medium – also depends on frequency and
temperature. In air, a non-dispersive medium, frequency is immaterial, temperature
(ϑ) however does matter. Applicable with sufficient accuracy:
cS(ϑ) = 331 m/s + (ϑ × 0,6) m/s
e. g. ϑ = +50 °C cS(+50) = 331 + 30 = 361 m/s

ϑ = +18 °C cS(+18) = 331 + 11 = 342 m/s
ϑ = -10 °C cS(-10) = 331 - 6 = 325 m/s
As an echo recognition unit, the USi safety requires twice the sound path:
If an object is detected at the distance d = 2 m, then the sound moves the distance s
= 2× d = 4 m until it is received again and evaluated by USi safety. The time required
for this is:
t(ϑ) = s / cS(ϑ)
z. B. ϑ = +50 °C t(+50) = 4 m / 361 m/s = 0.01108 s = 11.08 ms

ϑ = +18 °C t(+18) = 4 m / 342 m/s = 0.01169 s = 11.69 ms
ϑ = -10 °C t(-10) = 4 m / 325 m/s = 0.01231 s = 12.31 ms
The time difference depending on the temperature (ϑ) seems to be marginal but it
is not. However: A time difference of ∆t = 0.6 ms corresponds to a path difference of
∆s = 20 cm or a distance difference of ∆d = 10 cm. From a safety-related view, this is a
clear difference. Large temperature differences should therefore be avoided or com-
pensated by means of automatic temperature compensation.
Conclusion: In order to be able to guarantee a reliable protective device on the basis

of ultrasound, considering the prevalent temperature is indispensable.
The USi safety takes this insight into account: the system-related temperature drift
of 0.17 %/K must be allowed for via the temperature compensation parameter (see
chapter Setting temperature compensation).

Function
Calculating the protection field
Next to the approach speed, the response times of the entire control chain as well
as additional safety constants for the protection field design are of importance. The
basis for the observation of the minimum distance ( = minimum length of the protec-
tion field) is ISO 13855 “Safety of machinery; Positioning of safeguards with respect
to the approach speeds of parts of the human body”.
The minimum distance S describes the distance to the danger zone at which the pro-
tective device must react at the latest. If USi safety is installed directly at the danger
zone and aligned so that sound can spread parallel to the reference level (floor), then
minimum distance S and switching point SP1 are identical.
Machine
Danger zone
Minimum distance S
USi safety
sensor
Switch point SP1
Floor
The general calculation formula for the minimum distance S is:
S = minimum distance S = (K × T) + C
to the danger zone
[mm] For the approach speed K, the highest anticipated speed that results from the
K = approach speed movement of an approaching person and the individual movement of USi safety (e.g.
[mm/s] to FTS) must be used.
T = stopping time of the
entire system [s] The stopping time T describes the follow-up time of the entire system. This in-
C = additional safety cludes all times: the response time of the protective device, the response time of the
constant [mm] subsequent control and the stopping time of the dangerous movement.
The safety constant C defines an additional path as safety buffer and depends on
the definite application case.
If the protection field is installed parallel to the floor, the height of the protection
field above the reference level (floor) plays the decisive role for the safety constant C.
With an orthogonal set-up (e.g. sound curtain), the detection capacity of the protec-
tive device for the safety constant C is decisive.
Determined by the system, additional factors can also enter into the safety constant,
such as e.g. worst-case considerations on temperature differences.
It is generally sufficient to assume two cases – stationary hazard protection (e.g. ma-
chine) and mobile hazard protection (e.g. FTS).

Function
Minimum distance with stationary hazard protection
The stationary case is generally a machine with a man-machine interface in whose

area a dangerous movement takes place.
t1 = response time of the For stationary hazard protection, the minimum distance is S:
protecting device
t2 = stopping time of the S = (K × T) + C where: K = 1600 mm/s
machine T = t1 + t2
c1 = coefficient for the C = c1 + c2
configuration Consequent:
c2 = coefficient for high-
est temperature dif- S = (K × (t1 + t2)) + (c1 + c2)
ference
The approach speed K is assumed to be 1600 mm/s. That is equivalent to the step
speed according to ISO 13855.
The response time t₁ of the protective device results with USi safety from the measur-
ing frequency (30 Hz) and the multiplier multiple scan. The standard setting for multi-
ple scan (MS) is 3. That means that USi safety must register the same change in three
consecutive measurement cycles before it puts the OSSD in the OFF state.
That results in:
t1 = MS × (1/30 Hz) = (MS/30) s
e. g. MS = 3 t1 = (3/30) s = 0.1 s = 100 ms

MS = 10 t1 = (10/30) s = 0.333 s = 333 ms
The stopping time t₂ comprises the time between the receipt of the OFF signal in the
subsequent safety-related control system and the actual stoppage of the dangerous
movement.
Tip: The method for the The safety increase c₁ results from the configuration of the hazardous situation:
selection and configura- Height hazard, height protective device, layout protective device, sensor detection
tion of protective devices capacity as well as reference objects.
is described in ISO 13855
in Chapter 4. The safety increase c₂ is a system-caused increase. Since sound spreads with different
speeds at different temperatures (see Chapter Taking temperature into considera-
tion), this phenomenon must be considered if a consistent temperature cannot be
assumed.
The starting position is the temperature stored in the parameter temperature com-
pensation.
If additional higher temperatures are anticipated, the minimum distance is quasi
extended. From a safety-related point of view, a fail-safe situation. In this case, c₂ = 0.
If additional lower temperatures are anticipated, the minimum distance is quasi
reduced. From a safety-related point of view, this is critical. To stay on the safe side,
the maximum temperature difference ∆ϑ must be determined and the matching
safety increase c₂ must be selected.

Function
Coefficient c₂ as a function of temperature difference and measuring distance:

∆ϑ 5° 10° 15° 20° 25° 30° 35° 40° 45° 50° 55° 60° 65° 70° 75° 80°
Measuring distance d = 500 mm [0.85 mm/K]
c2 5 9 13 17 22 26 30 34 39 43 47 51 56 60 64 68
c2 9 17 26 34 43 51 60 68 77 85 94 102 111 119 128 136

c2 13 26 39 51 64 77 90 102 115 128 141 153 166 179 192 204

c2 17 34 51 68 85 102 119 136 153 170 187 204 221 238 255 272
The values were determined with the following formula:
c2 = ∆ϑ × 0.0017 × d [ mm ]
The result is rounded up to the next integer.
When you enter the lowest anticipated temperature for the temperature compen-
sation, USi safety will always work in the safe range but the minimum distance can
still be extended by up to 25 cm (255 mm).
Temperature sensor and factor c2

The factor c2 must always be taken into account. Also in case a temperature sensor
(optional) is connected. The sensor improves the performance substantially, but the
factor c2 still applies to the full extent._
If access to the danger zone is hampered by steps, the minimum distance S is re-
duced: 40 % of the step height H will be deducted.
Machine
Danger zone
S₂ = S₁ - (0.4 × H) Minimum distance S
USi safety
sensor
Platform with
safety mat
Floor Switch point SP1
If the USi safety sensor is not installed on the same level as the front edge of the dan-
ger zone in such a case, the switching point SP1 will be reduced appropriately.

Function
Minimum distance with mobile hazard protection
With mobile hazard protection, a single parameter is added – the travel speed k2 of
the mobile object.
k1 = approach speed S = (K × T) + C where: K = k2 - k1

k2 = travel speed T = t1 + t2
t1 = response time of the C = c1 + c2
protecting device Consequent:
t2 = stopping time of the
mobile object S = ((k2 - k1) × (t1 + t2)) + (c1 + c2) k1 = 1600 mm/s
c1 = coefficient for the
configuration The approach speed k₁ is the walking speed of the person approaching parallel to
c2 = coefficient for high- the reference axis.
est temperature dif-
ference If the person moves in another direction, only the vector that runs parallel to the
reference axis will be taken into consideration. This can be negative (person moving
toward USi safety) as well as positive (person by tendency moving away from USi
safety).
K = k2 - (-k1) K = k2 - k1
The travel speed k₂ of the USi safety results from the travel speed of the mobile object
plus the angular anticipated speed with cornering if the USi safety is installed outside
the centre of the object.
All other parameters are considered as with stationary hazard protection.

Function
Determining the validation
The temperature is taken into consideration, the protection field is designed opti-
mally and USi safety is parameterised appropriately – only the validation must still be
determined.
The validation is intended to confirm the correct design of the protection field by
testing the protection field with all essential test specimens, with all anticipated
speeds and with all anticipated temperatures.
The USi safety supports you in that with the protection field release including a pro-
tocol which records the user, the installation situation, the test specimen, the time as
well as the most important parameters.
Determining the test specimens

Whether a leg, body, head, arm, hand or even finger is to be detected, there is a
matching test specimen for every case. If several test specimens are possible, the se-
lection can possibly be reduced to the smallest test specimens:
If the test is positive with a small test specimen, a positive rest result can generally
also be expected with a larger test specimen.
Simulated body part Test specimen
Whole body
Arm, leg or shoulder
Head or hand
Finger (fingertip)
Tip: Table 2 in ISO 13856-
3 lists suitable test speci-
mens.
1 shows the preferred test direction.
Low-impedance test specimens are to be preferred over high-impedance test speci-

mens.

Function
Test speed and test direction

The highest anticipated approach speed should be selected for the test speed. That is
the same speed that was used for the calculation of the protection field length. Low-
er speeds are co-validated with the high test speed.
The test directions are oriented to the anticipated approach directions.
Test temperature
The test temperature should be the average anticipated temperature. That is the
same temperature that was entered for temperature compensation with the param-
eterisation of the USi safety.
The same test should additionally be performed with the lowest anticipated tem-
perature. The most important question hereby: Is the defined minimum distance
adhered to?
With the highest anticipated temperature, USi safety is – from a safety-related point
of view – on the safe side. Spot tests are recommendable. The question here: Is the
expanded minimum distance still tolerable?
Aids for validation

An illustration of the protection field on the floor or on the wall can be a big
help: e.g. drawn with chalk or an appropriately cut film. Depending on the alignment
of the sensor, either the width (±17°) or the narrow (±5°) sound beam is used as a ba-
sis, limited by the parameterised protection field length (= minimum distance).
The standard test routine in Chapter Function check can serve for a rough orienta-
tion.
Another source for validation ideas can be ISO 13855 “Safety of machinery; Position-
ing of safeguards with respect to the approach speeds of parts of the human body”.
Is the safeguard appropriate?

The PL required for the hazard must be decided by the integrator. This is followed by
the choice of safeguard.
Finally, the integrator needs to check whether the category and PL of the safeguard
chosen are appropriate.
Allowance for inherent limits

In addition to the safety technology analysis, the inherent limits of ultrasonic proximi-
ty switches must be considered:
•• Environmental conditions, (frost, swirling leaves, etc.)
•• Shape of the sonic lobe (asymmetrical funnel)
•• Reaction time (influence of diverse parameters)
•• Temperature compensation (highly fluctuating temperatures)

Function
Installation situation of the sensors

The installation situation of the sensors ( ultrasonic transducer) has a significant in-
fluence on the performance of the protective device. The three typical installation
situations are:
•• flush installation,
•• installation with funnel,
•• installation with reference object and
combinations thereof.
Flush installation
Inconspicuousness is the main charac-

teristic of flush installation. This makes
it the installation situation of first
choice if design issues have priority.
Also to be rated positive is the hidden
mounting that effectively prevents ma-
nipulation. Solely the accidental ma-
nipulation through suspended films,
cloths or the like directly in front of the
sensor (blind zone) is critical. “Open”
integration naturally provides acoustic noise sources from any direction the chance to
influence the sensor.
Installation with funnel
Installation with or in a funnel convinc-

es with high insensitivity to acoustic
noise sources that are at an obtuse
angle to the sensor. However, acoustic
noise sources at a sharp elbow can –
caused by the reinforcing funnel effect
– haven an even higher influence. With
a funnel, the sensor quasi no longer
has a blind zone: Suspended films and
the like are kept at a distance by the
funnel. This makes such objects detectable outside the blind zone and by USi safety.
However, a funnel permits the placement of a cotton ball directly in the blind zone.
This manipulation cannot be detected.
Installation with reference object
Installation with reference object means that a suitable reference object is integrat-
ed in the detection field of the sensor which is always positioned in the same place
and with the same alignment. During the release test, this object is detected as “set”
and subsequently treated as a basic prerequisite. If the reference object is no longer

Function
detected at its taught position – re-

gardless of whether removed, only
slightly displaced or through manipula-
tion (e.g. cotton ball in the funnel) – it
triggers the fail-safe mode. A random
number of reference objects can be
integrated. Each additional reference
object increases manipulation safety,
but at the same time, performance
drops because of possible false activa-
tions due to “wandering reference objects”. The “wandering” can be caused by great
temperature drifts but also by ageing of the sensor.
Suitable reference objects are those reflecting at least an 80 % echo and thus clearly
surpassing the internal threshold value.
This installation situation disregards whether the sensor is installed flush or with fun-
nel. This is rather an additional option to the two preceding installation situations.
Advantages and disadvantages
Installation Installation
Flush installation
with funnel with reference object
++ design integration ++ not sensitive to acoustic ++ tamper-resistant
++ for stationary and mo- noise sources at obtuse ++ ideal with stationary
bile application angles application
++ detect suspended films
++ for stationary and mo-
bile application
• tamper-resistant for the • the better, the longer • requires a suitable ob-
most part the funnel and the ject
smaller the diameter
-- sensitive to acoustic -- sensitive to acoustic -- sensitive to acoustic
noise sources noise sources at sharp noise sources
-- suspended films and angles -- false activations
the like are not detect- -- additional length through temperature
ed in the blind zone -- simple manipulation drift
with cotton balls -- false activations
through ageing
Installation position of the temperature sensor

The temperature sensor (optional) can be installed in any position. Mayser recom-
mends positioning the temperature sensor near the sensor (ultrasonic transducer).
Temperature compensation by means of the temperature sensor is always applied to
both evaluations, to sensor 1 and sensor 2. A substantial difference in temperature
between the operating ranges of sensor 1 and sensor 2 necessitates two separate
evaluation units.

Installation
Installation
The design of the protection field comes before the assembly (see Chapter Designing
the protection field). This sometimes determines at which position, which height and
in which direction a sensor is to be attached.
The installation includes four individual installation steps:

1. Mounting the sensor (ultrasonic transducer)
2. Mounting the temperature sensor (optional)
3. Mounting the evaluation unit
4. 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 sonification 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 30 Hz, 30
crackles per second are audible. This can be stressful when continuous. Here, it is rec-
ommended to not align the sensor directly to the ears, but at an angle of at least 20°.
The same applies for indirect sonification reflected from hard reflectors like e.g. walls.
As an alternative, parameterisation software can be used to reduce transmission in-
tensity – however, to the detriment of the detection capacity.
Key for safe function
There are some points that, if appropriately taken into consideration, form the best
basis for safe sensor function.
When you observe the following points during sensor assembly, safe function is near-
ly guaranteed:
ÄÄ First check the attachment site: At what position, in which alignment, at which
height can the protective device be installed optimally and tamper-resistant?
ÄÄ Avoid pressure on the sensors.

Pressure may be exerted only on the O-rings, not on the sensor housing itself.
ÄÄ Install the sensor so that the active surface is preferably flush with the front edge
of the danger zone.
ÄÄ Avoid EMC noise sources in the immediate vicinity of the sensors and their cables.
ÄÄ Avoid strong acoustic noise sources in the immediate vicinity of the sensors or at
sharp angles to the active surfaces.

Installation
ÄÄ Avoid strong temperature fluctuations.
ÄÄ Prevent accidental manipulation.

E.g. with safety screws, with the integration of sensors so that no films or the like
can be thrown over, with reference objects in the detection field and other solu-
tions.
1. Mount the lower section of the

housing at the intended position.
Use the M5 screws that are includ-
ed.
2. Place an O-ring in each of the sen-

sor grooves.
3. Position the sensor in the lower

section of the housing so that the
O-rings are in the grooves and the
cable lies loosely in the cable bush-
ing.
4. Carefully set the upper section of the housing in place.
5. When the upper section of the

housing is level and the cable is
loose in the cable bushing, bolt the
upper section to the lower section
with the M3 screws included.
6. Route the sensor cables with no tension and at a sufficient distance to sources of
electromagnetic interference, such as DC motors.

Installation
CAUTION Functional impairment through EMC noise sources

Electromagnetic noise sources in the immediate vicinity of the sensors and their
cables can cause malfunctioning.
ÄÄ Position the sensors with sufficient distance to the noise sources.
ÄÄ Install the cables with sufficient distance to the noise sources.
Alternative 1: use your own mounts
Instead of the housing sets from Mayser you can also use your own mounts. They can
be simple (standard mounting fixture) or integrated (optimised mounting fixture). In
both cases, certain dimensions must be allowed for. Use only O-rings from Mayser for
fastening the sensor in the mount. The primary function of the O-rings is to provide
acoustic decoupling.
Standard mounting fixture Optimised mounting fixture

– clamping version – – integrated version –
Sensor:
Dimensions
Tolerances: ISO 2768-1 c Tolerances: ISO 2768-1 m

with O-rings 18.0 × 2.5 mm with O-rings 17.5 × 2.0 mm
Part number 7502819 (optional) Part number 7502820 (optional)
1. Place one O-ring in each of the

grooves N1 and N2 of the sensor.
2. Attach the sensors (ultrasonic

transducer) in a random position
in tamper-proof (e.g. with safety
screws) holders.

Installation
WARNUNG Failure of the protective function through manipulation

Freely accessible standard screws are not manipulation-proof. Releasing the screws
and twisting the sensor can completely cancel the protective function.
ÄÄ Preferably attach the sensor with safety screws.
ÄÄ Hide the standard screws under a lockable cover.
CAUTION Functional impairment due to incorrect mounting

Squeezing the sensor – particularly in the front area near the active surface – can
cause malfunctions and mechanical damage.
ÄÄ Only attach the sensor with the recommended O-rings.
ÄÄ Do not use the cable as a pulling aid. The cable can tear off.
ÄÄ Avoid high mechanical loads on the active surface (heavy pressure, impact, etc.)
when mounting.
ÄÄ Immediately replace damaged sensor (torn off cable, damaged active surface).
Repairs are not possible.
A cross-section of a mounted sensor
1 Sensor
2 Active surface
3 Optimised holder
4 O-rings
5 Cable
Alternative 2: M30 housing
Another mounting option is the M30

housing (optional). The M30 housing
with the cut-to-size sensor (ultrasonic
transducer) is available as an accessory.
This allows mounting of the sensor on
standard M30 mounts.
ÄÄ Use anti-twist protection to pre-

vent axial twisting of the detection
field.
ÄÄ Take the geometry of the sonic lobe into consideration (see chapter Sonic lobe).

Installation
Mounting the temperature sensor

The temperature sensor (optional) measures the temperature of the air medium to
ensure maximum performance of the USi safety. The temperature sensor should be
positioned as near as possible to the sensor, and outside of the sonic lobe.
For mounting you will additionally need a suitable M3 spacer and an M3 screw con-
nection.
1 Temperature sensor
2 Mounting tab
3 M3 screw connection
4 Spacer
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 degree of protec-
tion drops to IP20. The opening for the USB connection should therefore be config-
ured 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).
ÄÄ For automated guided vehicles (AGV): Take measures to ensure that the housing
remains insulated from the AVG chassis.

Installation
ÄÄ Fix the evaluation unit in any position with two screws Ø 3 mm.
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 evalua-
tion unit. The screws are now captive.
ÄÄ When performing these actions, avoid touching and soiling the electronics.
ÄÄ Ensure the correct seat of the seal in the lid.
ÄÄ Put on the cover so that the designations of the connections point to the side
with the connections.
Wiring the unit cable

WARNING Danger of injury due to electrocution
ÄÄ Disconnect all devices and live parts in the immediate environment of the pow-
er supply and protect them against being switched on again (see relevant oper-
ating instructions).
ÄÄ Check that all devices and parts are disconnected from the power supply.
Lead color Signal USi safety

Brown +US
DC 24 V (DC 21 to 28 V)
Blue -US
White OSSD 1.1 max. 150 mA / max. US
Green OSSD 1.2 max. 150 mA / max. US
Yellow OSSD 2.1 max. 150 mA / max. US
Grey OSSD 2.2 max. 150 mA / max. US
Pink OUT 1 max. 150 mA / max. US
Red OUT 2 max. 150 mA / max. US
ÄÄ Wire the strands of the unit cable that have been equipped with wire and
sleeves.

Installation
on machines (stationary) on AVGs (mobile)

The following action is possible, but
ÄÄ Use only voltage sources of the not absolutely necessary:
type SELV that you wire in the
switch cabinet into a PELV power ÄÄ Connect the housing (evaluation
circuit. unit) and AVG chassis by means of
a parallel RC element.
ÄÄ Make sure to observe the require-

ments of EN 1175-1.
CAUTION Failure due to incorrect wiring
ÄÄ Check the wiring carefully. The shielding braid must not be connected.
ÄÄ Inspect the supply voltage.
ÄÄ Check the external voltage supply: Does is comply with the requirements of IEC
60204-1?
Safe wiring of OSSDs

The OSSD safety outputs are auto- Test pulse
matically tested by the USi safety at
ON
regular intervals. The internal test pulse
needed for this temporarily (< 400 µs)
OFF
switches the single OSSDs to OFF state.
A downstream control system must be
able to tolerate these test pulses.
The following is recommended for safe wiring of the OSSDs.
ÄÄ Always connect the single OSSDs separately from each other.
ÄÄ Make sure that the downstream control system processes the single OSSD signals
separately from each other.
ÄÄ Make sure that the downstream control system tolerates OFF states of < 400 µs.
ÄÄ Connect only one downstream safety element for each OSSD.
ÄÄ If additional safety elements are needed, choose a suitable contact duplication.
ÄÄ Make sure that downstream protection devices are force-guided and monitored.

Commissioning
Commissioning
The evaluation unit expects that at least one sensor (ultrasonic transducer) is con-
nected. If only one sensor (ultrasonic transducer) is used, then this must be connect-
ed to “U1”.
1. Connect the sensor (ultrasonic transducer), the temperature sensor (optional)

and the unit cable with the evaluation unit.
2. Make sure that the plug connectors are firmly mounted.
3. Check the supply voltage:

-- Is this available via a PELV circuit?
-- Is the external fusing with 2 A slow-blowing set up?
4. Connect the supply voltage.
ÄÄ Never disconnect terminals with the power on.

ÄÄ Never unplug plug connections with the power on.

Commissioning
First commissioning
During the first commissioning, the standard passwords must be replaced with in-
dividual passwords. This transfers the responsibility to the USi safety operator. The
operator is responsible for the correct setting of the safety sensor.
After applying the supply voltage, USi safety signals the readiness for first commis-
sioning: All LEDs OSSD light up in red, the LED OUT 1 lights up in yellow, the LEDs
power, warning and fault form a moving light. USi safety stays in this state until the
password procedure has been completed successfully.
1. Connect USi safety to your computer via the USB interface. Insert the USB plug
completely into the USB socket of USi safety applying only slight pressure.
Without screw plug, only degree of protection of IP20!
ÄÄ Check the environment of the evaluation unit: Is operation with IP20 possible?
ÄÄ If not: see the Chapter Installing the evaluation unit.
2. Start the USi safety GUI on your computer.
3. In the tab Log in/out, enter the password for level 2: Mayser2.
4. Assign new passwords for level 1 (Mayser1) and level 2 (Mayser2). Condition: at
least four different characters. Avoid using similar passwords for level 1 and lev-
el 2.
USi safety is now ready for the release test: The LEDs power and Warning are lit con-
stantly, LED fault is off, the sensor cracks audibly.
The USi safety GUI has switched to the tab Standard.
5. Check the settings in the tab Standard: Do the parameter meet your require-
ments?
6. If not: Change the parameters appropriately.
7. If yes: Click Write parameters and carry out the release test (see Chapter Re-
lease).
The complete password procedure is required only during the first commissioning.

Commissioning
Log in
Every start of the parameterisation software requires a password entry in the tab Log
in/out, either at level 1 (Display only) or at level 2 (Display and parameterisation). USi
safety is already working with the parameters released last. You have to log in to view
these or change specific parameters or to be able to use the diagnosis.
How to log in at level 1:
ÄÄ In the tab Log in/out, enter the password for level 1 defined by the operator.
If the log-in was successful, the parameterisation software shows the tab Standard.
All settings in the tabs Standard and Expert mode (if activated) are visible, howev-
er, they cannot be changed.
How to log in at level 2:
ÄÄ In the tab Log in/out, enter the password for level 2 defined by the operator.
If the log-in was successful, the parameterisation software shows the tab Standard.
All settings in the tabs Standard and Expert mode (if activated) are visible and can
be changed.
Changes parameters are effective only after they have been transferred to USi safe-
ty with a click on Writing parameters and the subsequent release test was run
through successfully.
Password for the evaluation unit

The entered password does not give you access to the parameterisation software
but to the connected evaluation unit. That means, the assigned passwords apply
exclusively to the USi safety currently connected to the USB port. Other device, oth-
er password.
ÄÄ Always remember the passwords in connection with the serial number (Serial
No.) on the rating plate of the evaluation unit.
For demonstration purposes

If you do not log in and instead confirm the offline mode by clicking on More, then
you can show the two tabs Standard and Expert mode for demonstration purpos-
es and change all parameters. This does not affect the possibly connected USi safety.
The key Writing parameters is deactivated.

Commissioning
Approval
The release test is required in two cases: During the first commissioning and after
every parameter writing. It comprises the functions performing a teach-in, deter-
mining transducer data and checking the protection field. To test the protection field,
you need a suitable test specimen (see Chapter Determining the validation).
The release test is possible only at log-in level 2.
How to carry out the release test:
1. In the tab Standard in the group field Area distribution, enter the distances for
the protection field and the warning field.
Standard: Protection field 200 cm, warning field 200 cm (operating mode 1
range).
Entries can later be corrected at any time, roughly estimated values are complete-
ly sufficient initially.
2. Click on Writing parameters.
3. Make sure there is nothing in the detection field that normally does not belong
there.
4. Switch to the tab Release.
5. Click on Start release and wait until the two check marks appear next to Teach
In and Setting transducer data (f0).
6. Take a suitable test specimen slowly from the outside across the switching point
in the direction of sensor 1 (ultrasonic transducer). Observe the tab Release:
Every detected partial area is hidden. If the complete protection field of sensor 1
was detected, the GUI shows a green bar as well as a red check mark in the field
Distance transducer 1.
For verification: If the test sample is detected, the LED “OUT 1” lights up.

Commissioning
7. Remove the test specimen from the detection field and wait until the GUI is ready
to check the protection field of sensor 2.
8. Take a suitable test specimen slowly from the outside across the switching point
in the direction of sensor 2 (ultrasonic transducer). Observe the tab Release:
Every detected partial area is hidden. If the complete protection field of sensor 2
was detected, the GUI shows a green bar as well as a red check mark in the field
Distance transducer 2.
For verification: If the test sample is detected, the LED “OUT 2” lights up.
9. Remove the test specimen from the detection field.
10. Click on Acknowledge.
11. Continue to keep the detection field empty until point 12 has been carried out.
12. Enter your name, the type of application and the test specimen used in the fol-
lowing three windows.
The parameterisation software uses it to automatically produce a protocol with your
information and the most important parameters. The LEDs of the outputs OSSD
switch from red to green. The LED “Warning” is no longer lit.
The parameterisation software switches to the Protocol tab.
13. To print the protocol click Print protocol.
14. Sign and archive the protocol.
USi safety is now ready to monitor the set areas.

The only thing missing for safe operation missing is the functional test (see Chapter
Function check).

Commissioning
Protection field testing

With every commissioning (applying of supply voltage), USi safety autonomously
starts the internal system test, initialises the sensors (ultrasonic transducers) and then
waits for the protection field test. This does not require the parameterisation soft-
ware.
The safe outputs OSSD are blocked, the LED “OSSD” are lit red. The LED “Power” flash-
es.
USi safety only releases the safe outputs OSSD when the protection field test was
successful. USi safety is then operational.
How to perform a protection field test:
1. Enter a suitable test specimen (see Chapter Determining the validation) into the
second half of the protection field (see diagram).
2. Observe the signal outputs OUT: If the LEDs “OUT” and “Power” are lit perma-
nently, USi safety has detected the test specimen.
3. Do not remove the test specimen before the green LED “Power” is lit permanent-
ly.
USi safety acknowledges the successful protection field test by releasing the safe out-
puts OSSD. The LEDs “OSSD” switch to green.
Cancelling the protection field test

For applications in which it is counter-productive to conduct the protection field test
each time the supply voltage is applied, the protection field testing can be cancelled
with the parameterisation software (see Cancelling the power-on start interlock).

Commissioning
Testing
The following description applies to USi safety with two sensors and two defined are-
as each (warning and protection field).
For USi safety with only one sensor, the functional test is completed after Step 4.
For USi safety without warning field, steps 2 and 6 are omitted.
1. Make sure that the detection fields from sensor 1 and sensor 2 are clear.
-- green LED “Power“ is on
-- all LEDs “OSSD” are lit green
-- all OSSD Outputs are closed
2. Enter an object into the warning field of sensor 1. Make sure that the detection
field of sensor 2 remains clear.
-- LEDs “OSSD 1.1“ and “OSSD 1.2“ are lit green
-- Outputs OSSD 1.1 and OSSD 1.2 are closed
-- yellow LED “OUT 1” is on
-- LEDs “OSSD 2.1“ and “OUT 2.2“are lit green
3. Repeat step 1.
4. Enter an object in the protection field of sensor 1. Make sure that the detection
-- LEDs “OSSD 1.1“ and “OSSD 1.2“ are lit red
-- Outputs OSSD 1.1 and OSSD 1.2 are open
-- LEDs “OSSD 2.1“ and “OUT 2.2“ are lit green
5. Repeat step 1.
6. Enter an object into the warning field of sensor 2. Make sure that the detection
7. Repeat step 1.

Commissioning
8. Enter an object in the protection field of sensor 2. Make sure that the detection
-- LEDs “OSSD 2.1“ and “OUT 2.2“ are lit red
-- Outputs OSSD 2.1 and OSSD 2.2 are open
All tests passed? – If so, your USi safety is now ready for operation.
Recording the protocol

Modern industrial safety management requires verifications. The USi safety GUI ac-
commodates this demand in the tab Protocol. After successful release, a protocol is
automatically generated here which you can finally print, sign and archive.
Start release and Print protocol are possible only at log-in level 2.
How to generate a protocol:
1. Carry out the release test (see Chapter Release).
2. After clicking on Acknowledge, enter your name, the application and the test
specimen used.
The protocol is automatically generated and displayed.

Commissioning
3. To print the protocol click Print protocol.
Tip: For digital archiving, select a PDF-generating printer, sign the PDF digitally and
save it.
The protocol can also be saved in the USi proprietary format SIP. For this purpose, the
Protocol tab features the button Save protocol....
1. Click on Save protocol....
2. Assign a descriptive file name, preferably including the date.
Protocols that have been saved in this way can be displayed at any time by the pa-
rameterisation software in the Protocol tab:
1. Click on Load protocol.
2. Select the desired file.
System restart
WARNING Danger of injury
ÄÄ Never start your machine as long as the danger remains.
Automatic reset
USi safety operates without reset function. As soon as the protection field is empty
again, USi safety switches with a delay of tW, back to the original state, the OSSD out-
puts are in ON state, and the OSSD LEDs light up green.
Delay tW is equivalent to the automatic restart delay. As standard, 0 measurement
cycles (tW = 0 ms) are preset.
Without reset function

When a safeguard without a reset function is used (automatic reset), the reset func-
tion must be made available in some other way.
ÄÄ After the restart, check the function (see Chapter Function check).

Correlations
LEDs Meaning
211019 v2.00
Power Warning Fault OSSD 1.1 OSSD 1.2 OUT 1 OSSD 2.1 OSSD 2.2 OUT 2
Output 1 Output 2 LED off: LED on: LED flashes:
green yellow red green/red green/red yellow green/red green/red yellow
USi safety is without voltage supply.
After the first commissioning: LEDs “Power”, “Warning” and “Fault”

flash like a moving light from the bottom to the top. USi safety now
waits for the passwords for level 1 and level 2 to be entered anew.
After renewed commissioning: LED “Power” flashes, LEDs “OSSD”

are lit red. USi safety waits for the protection field test.
LEDs “OSSD 1.X” are lit green, LEDs “OSSD 2.X” are lit red: USi safety
is operational with one sensor. Sensor 2 is logged off.
LEDs “OSSD 1.X” are lit green, LED “OUT 1” lights up, LEDs “OSSD
2.X” are lit red: USi safety is operational with one sensor, one object
is detected in the warning field.
LEDs “OSSD 1.X” are lit red, LED “OUT 1” lights up, LEDs “OSSD 2.X”
are lit red: USi safety is operational with one sensor, one object is
Operating Instructions USi safety

detected in the protection field.
LEDs “Power” and “OSSD” are lit green: The USi safety is in opera-
tion with two sensors, the detection field is empty.
LEDs “Power” and “OSSD” are lit green: USi safety is operational
with two sensors, one object is detected in the warning field of sen-
sor 2.
LEDs “Power” and “OSSD” are lit green: USi safety is operational
with two sensors, one object is detected in the protection field of
sensor 2.
LEDs “OSSD 1.X” light up green, LEDs “OSSD 2.X” light up red, LEDs
“OUT 1” and “OUT 2” are on: USi safety operates with two sensors;
one object is detected in the warning field of sensor 1 and another
is detected in the protection field of sensor 2.
Page 43/107
Commissioning
Correlations (continued)
LEDs Meaning
Page 44/107
Power Warning Fault OSSD 1.1 OSSD 1.2 OUT 1 OSSD 2.1 OSSD 2.2 OUT 2
Output 1 Output 2 LED off: LED on: LED flashes:
green yellow red green/red green/red yellow green/red green/red yellow
LEDs “OSSD” light up red, LEDs “OUT 1“ and “OUT 2” are on: USi
safety operates with two sensors; one object is detected in the pro-
tection field of sensor 1 and another is detected in the protection
field of sensor 2.
LEDs “Power“ and “Warning” are lit, LEDs “OSSD” are lit red. The pa-
rameters were changed, USi safety waits for the release test.
LED “Warning” flashes: USi safety is operational with one sensor, a

critical operating state announces itself.
LED “Warning” flashes: USi safety is operational with two sensors, a

critical operating state announces itself.
LED “Fault” lights up, LED “Warning” is not lit, LEDs “OSSD” are lit
red. USi safety has detected a fatal error and went into the fail-safe
mode. The parameterisation software provides information on the
fault under Extras/Read fault status.
Operating instructions USi safety

211019 v2.00
Commissioning
Adjust settings
Adjust settings
If you did not make any changes in the tab Standard during the first commission-
ing, you must confirm the factory settings by clicking Writing parameters. After a
successful release test, USi safety starts with the factory settings (see Chapter Factory
settings):
Sensor 1
Protection field range normal (up to 200 cm)
Protection field 200 cm
Warning field 200 cm
Signal outputs OUT NO contact (high-active)
Power-on start interlock with protection field test
Restart delay 0 measurement cycles
In very few cases will the factory settings be right for your application case. In the
tab Standard, you can change all parameters listed above at any time with the ex-
ception of the second sensor. This must be logged in or out in the Extras menu (see
Chapter Logging sensor 2 in and out).
In this chapter, you will find out interesting facts about:

•• Overview of the Standard tab
•• Logging sensor 2 in and out
•• Specifying the protection field range
•• Dividing an area
•• Defining signal outputs OUT
•• Cancelling the power-on start interlock
•• Specifying the restart delay
How to change settings:
1. Connect USi safety to your computer via the USB interface. Insert the USB plug
completely into the USB socket of USi safety applying only slight pressure.
Without screw plug, only degree of protection of IP20!
ÄÄ If not: see the Chapter Installing the evaluation unit.
2. Start the parameterisation software USi safety on your computer.
3. Log in at level 2.
4. Change random settings as described in the next chapters.

Adjust settings
Overview of the Standard tab

For most application cases it is sufficient to make the basic settings in the Standard
tab and transmit them to USi safety with a click on Write parameters.
Parameters for sensor 1 (transducer 1)

Parameter for sensor 1 and 2 (transducers 1 and 2)
Visualisation: Protection field and warning field
Protection field range
Area division

Sensor 1 (transducer 1)
Area division
Sensor 1 (transducer 1) Signal outputs OUT

and Power-on start interlock
sensor 2 (transducer 2) Restart delay

Sensor 2 (transducer 2)
Area division

Adjust settings
Logon/logoff sensor 2
The USi safety is preset to one sensor (ultrasonic transducer) on sensor 1 when sup-
plied. If a second sensor (ultrasonic transducer) is required, sensor 2 must be logged
on. Sensor 1 must always remain connected; it may not be logged off.
The function Transducer 2 log can be found in the Extras menu.
This is how to logon sensor 2:
1. Click Transducer 2 log in in the Extras menu.
The tab Standard displays the group field Transducer 2. The parameter fields for
transducer 2 are activated. The parameters set in group field Transducers 1 and 2
now also apply to sensor 2.
2. Enter the parameters for protection and warning field for sensor 2 (see Chapter
Area division).
Tip: Before you release the new settings, you can check the effects in the tab Diag-
nosis with fixed echo and correct the settings again, if necessary.
USi safety immediately starts to work with two sensors.
This is how to logoff sensor 2:
1. Log out Transducer 2 log in the Extras menu.
The tab Standard displays the group field Transducer 2. The parameter fields for
transducer 2 are deactivated. The parameters set in group field Transducers 1 and 2
now only apply to sensor 1.
USi safety immediately starts to work with sensor 1 only.

Adjust settings
Specifying the protection field range

The range of the protection field is limited to 200 cm with the option normal. If nec-
essary, the option can be expanded (reference axis only) to extend the protec-
tion field range to 250 cm. Prerequisite: The objects to be detected should be in the
immediate vicinity of the reference axis.
The range of the warning field cannot be expanded. That means that depending
on the protection field range, the warning field can be relatively small or completely
omitted.
Normal is preset as standard.
How to set the protection field range:
1. Click on Expanded (reference axis only) in the group field Protection field
range.
2. Enter the new parameters for protection and warning field (see Chapter Area
division).
USi safety immediately starts to work with the expanded protection field range.
Normal or expanded?
To implement continuous sound-absorbing curtains with multiple sensors next to
each other, the default protection field range setting is normal (max. 200 cm). At
200 cm the expansion of the sonic lobes is wide enough for a safe evaluation. Be-
yond 200 cm the sonic lobes taper off drastically, so that gaps in the detection can
occur.
On the other hand, the protection field range can be set to expanded (reference
axis only) for single sensors, if the prerequisite (see above) is fulfilled.

Adjust settings
Dividing an area
USi safety knows two operating modes: Operating mode 1 range and operating
mode 2 ranges. If the switching points are identical (SP1 = SP2), USi safety works in
operating mode 1 range – protection field only.
For the operating mode 2 ranges – protection field and warning field – the switching
points for protection and warning field must differ. The switching point for the warn-
ing field must be larger than that for the protection field (SP2 > SP1).
The warning field influences only the outputs OUT. The outputs OSSD are influenced
exclusively by the protection field.
In the group field Area division, you define the switching points for protection field
and warning field in centimetres.
Possible values for switching point SP1 (protection field) are 15 to 200 cm.
Possible values for switching point SP2 (warning field) are up to 250 cm.
The switching points SP1 = 200 cm and SP2 = 200 cm are preset as standard for
each sensor.
How to change the area division:
1. Enter the new value for SP1 in the field Protection field.
-- The entry must be a natural number
-- for sensor 1 in group field Transducer 1
2. Enter the new value for SP2 in the field Warning field.
-- The entry must be a natural number
USi safety immediately starts to work with the newly set area division.

Adjust settings
Defining signal outputs OUT

Every sensor (ultrasonic transducer) is assigned one signal output OUT each. This is
actuated by both, from the respective protection and warning field. If an object is
outside the protection field but within the warning field, then the object is detected
only in the warning field. The signal output OUT changes its state; however, the safe
outputs OSSD do not.
•• Sensor 1: OUT1
•• Sensor 2: OUT2
The signal outputs are always set jointly: as NO contact or NC contact. They are out-
puts of the type PNP.
The signal outputs OUT are set in the tab Standard.
The signal outputs OUT are preset as NO contacts.
How to set the signal outputs OUT:
1. Select the option High active (NO contact) or Low active (NC contact) in the
group field Signal outputs OUT.
USi safety immediately starts to work with the new setting for the signal outputs
OUT.
4. Check the signal outputs OUT.

-- High active (NO contact): LED “OUT” lights up as soon as an object is de-
tected in the protection or warning field.
-- Low active (NC contact): LED “OUT” lights up as long as protection and
warning field are empty.
High active (NO contact) Low active (NC contact)

PNP
LED off: LED on:

Adjust settings
Cancelling the power-on start interlock

Each time the supply voltage is applied anew, USi safety starts up with the Power-on
start interlock, after which USi-safety is locked until the detection capability has been
successfully tested. All LEDs “OSSD” are lit red. The LED “Power” flashes.
This state changes only if the USi safety detects a test object between the half and
full preset protection field distance. Once USi-safety has accepted the test object it
must be removed from the protection field. Afterwards, the OSSDs are released. The
LEDs “OSSD” are lit green. The LED “Power” is lit permanently. USi safety works with
the parameters released last.
USi safety thus actively supports the demand for a regular functional test. This short
test – called protection field test – does not replace the test of the detection field as
it is carried out during the release test. If you want to check the complete detection
field after each renewed application of the supply voltage, you can – as an alternative
to the protection field test – carry out the release test in the tab Release.
If you manage the regular functional test in another manner, then you can cancel the
power-on start interlock. USi safety then immediately starts working with the param-
eters release last after application of the supply voltage.
With protection field test is preset as standard.
How to cancel the power-on start interlock:
1. Click on Without protection field test in the group field Power-on start in-
terlock.
USi safety then immediately starts working without power-on start interlock. After
renewed application of supply voltage, USi safety immediately starts the monitoring
of the detection field.

Adjust settings
Specifying the restart delay

USi safety has no input for manual reset and no input for cancelling a restart lockout.
Instead, USi safety features a time-delay element – the restart delay.
With the restart delay, you can have the safe outputs OSSD stay in the safe state for
a short time as soon as the previously detected object was detected as “has left the
detection field”.
The delay can be specified for the range from 0 to 8.25 s. The restart delay is specified
as the number of measurement cycles passed. In the factory settings, a measurement
cycle is equivalent to approximately 33 ms, one samples is thus equivalent to 30
measurement cycles.
As standard, 0 measurement cycles are preset.
How to set the restart delay:
1. Enter the required value in the field Restart delay.
USi safety immediately starts to work with the newly specified restart delay.
4. Check the LEDs “OSSD”.

-- Is the delay time too short? Then increase the value.
-- Is the delay time too long? Then reduce the value.

Adjust settings
Saving settings
Is USi safety working reliably with its new settings?
Then it is high time to save these settings in order to be able to fall back on them
again later on.
How to save settings:
1. Click on Save parameters... in the File menu.
2. Select the storage location (folder).
3. Enter an unmistakable name in the field File name (e.g. machine type, safety
hazard, position of the protective device and the like).
4. Click on Save.
The settings are now saved as filename.usi.

Adjust settings
Loading settings
Additional optimisation has failed. Do you want to restore the original settings?
Or do you have a small series of machine for which hazard protection is to be uniform
and defined?
Then load the settings that you have previously saved into the parameterisation soft-
ware and transmit them to USi safety.
How to load settings:
1. Click on Load parameters in the File menu.
2. Select the storage location (folder).
3. Select the file with the required settings.
4. Click on Open.
The settings are now loaded into the parameterisation software.

The settings are now transmitted to USi safety.

Adjust settings
Changing the password

As a protective device, USi safety is always subjected to the danger of manipulation.
The most effective type of manipulation is the access of unauthorised persons to
parameters via the level 2 password. To avoid this, the level 2 password should be
changed regularly (tip: monthly).
During the first commissioning, you will be asked to assign new passwords for level
1 as well as level 2. You will later change either the password for level 1 or the pass-
word for level 2 – depending on the level you are currently in.
As standard, the password for level 1 is preset to be Mayser1 and Mayser2 for level
2.
Password for the evaluation unit

The entered password does not give you access to the parameterisation software
but to the connected evaluation unit. That means, the assigned passwords apply
exclusively to the USi safety currently connected to the USB port: Other device, oth-
er password!
ÄÄ Always remember the passwords in connection with the serial number (Serial
No.) on the rating plate of the evaluation unit.
How to change the password for level 2:
1. Log in at level 2 in the tab Log in/out.
2. Click on Changing the password in the Extras menu.
3. Enter the previous password for level 2 in the first field.
4. Enter the new password for level 2 in the second field.

Condition: At least four different characters.
5. Repeat the entry in the third field.
6. Acknowledge your entry with a click on OK.
After that, you can log into level 2 only with the new password.

Adjust settings
Access to USi safety via level 1 is less critical because read access only is assigned with
this access. Changing parameters in level 1 is not possible.
How to change the password for level 1:
1. Log in at level 1 in the tab Log in/out.
2. Click on Changing the password in the Extras menu.
3. Enter the previous password for level 1 in the first field.
4. Enter the new password for level 1 in the second field.

Condition: At least four different characters.
5. Repeat the entry in the third field.
6. Acknowledge your entry with a click on OK.
After that, you can log into level 1 only with the new password.

Adjust settings
Reset parameters
Did you take optimisation too far? Changed too many parameters? Lost track of the
parameters which were changed last? – Sometimes, only a restart can help. USi safety
supports this with the function Reset parameters to Standard: All parameters are
reset to factory settings and the function Write parameters is executed. USi safety
now waits only for the release.
The function Reset parameters to standard can be found in the Extras menu.
How to reset the parameters:
1. Click on Reset parameters to standard in the Extras menu.
2. Click on the connected device in the submenu.
3. Acknowledge the confirmation prompt with Yes.

The GUI now replaces all parameters with the factory settings and automatically
starts the function Write parameters.
USi safety immediately starts working with the factory settings again.
5. Restart your attempt to adjust USi safety to your application.

Adjust settings
Carrying out a RESET

In rare cases, it can happen that USi safety does not exit a once entered error mode
on its own. In this case, only a restart helps; during operation also called a reset.
Whether the restart is initiated via hardware (disconnect supply voltage) or via soft-
ware (click RESET) is not important here. In both cases, the safe outputs OSSD are
deenergized, the evaluation unit starts again.
The function RESET can be found in the Extras menu.
How to carry out a reset:
1. Click on RESET in the Extras menu.
2. Acknowledge the confirmation prompt with Yes.
USi safety now starts working with the parameter released last again.
If USi safety unexpectedly enters fault mode again:
4. Read out the fault status (see Read fault status).

Adjust settings
Read fault status

In the case of faults for which the cause is not obvious, the function Read fault sta-
tus may be helpful. After opening the window, the fault code, a description of the
fault and a possible remedy are displayed. In addition, two routines for troubleshoot-
ing are offered: Switch to diagnosis and Delivery condition.
Switch to diagnosis causes USi safety to exit its fault state (no diagnosis possible)
and the GUI switches to the Diagnosis tab. To make the switch, the functions Write
parameters, RESET and View in the Diagnosis tab are executed in sequence. Now di-
agnosis is again possible.
Delivery condition causes all parameters in the evaluation unit to be overwritten

with the factory settings. Afterwards, the evaluation unit is again in delivery condi-
tion.
How to read out the fault status:
1. In the Extras menu click Read fault status.
2. Read the fault descriptions.
3. Follow the instructions for troubleshooting.

Adjust settings
Send info to Mayser

In case of persistent problems, we recommend contacting Mayser Support at
info.usi@mayser.de. In order to provide assistance for a specific problem, Mayser
Support requires extensive information. For this purpose the parameterisation soft-
ware offers the function Info to Mayser. This function automatically generates an
e-mail with five screenshots attached. The screenshots show the tabs Standard, Ex-
pert mode and Diagnosis as well as the message windows for Read fault status
and Info. To allow the user to add additional information about the particular appli-
cation case, the e-mail is not sent automatically.
In order to generate the screenshots, your system’s display settings must be config-
ured for a scaling factor of 100 %.
How to send information to Mayser:
1. In the Extras menu click Info to Mayser.
2. Add additional information to the generated e-mail.
3. Click on Send.

Adjust settings
Logging out USi safety

All settings have been made. USi safety should now continue to work independently.
You can then log USi safety out of the GUI (parameterisation software).
How to log out the USi safety:
1. Click on Log out in the tab Log in/out.
2. Disconnect the USB connection.
USi safety is now logged out.

A restored USB connection becomes effective only after you have logged in the tab
Log in/out once and logged back into level 1 or level 2.
3. Carefully screw on the screw plug.
The evaluation unit now has the degree of protection of IP65 again.
Functional impairment through missing screw plug!
ÄÄ If not: Deactivate the device.
ÄÄ Replace a damaged or lost screw plug only with original Mayser plugs.
Automatic log-out
As soon as you have logged into the parameterisation software, a countdown of 5

minutes starts. Each activity in the peripheral equipment (e.g. mouse or keyboard) of
your computer restarts this countdown from the beginning.
When the countdown is elapsed, i.e. your computer has had no activity in the pe-
ripheral equipment for 5 minutes, USi safety will logged out automatically for safety
reasons.

Adjust settings
Changing the language

The GUI of the parameterisation software starts up in German if German was set as
the standard language in the system settings during installation of the software. If
German was not set as the standard language during installation, it starts up in Eng-
lish.
The GUI can also be displayed in other languages. It always starts up in the last lan-
guage that was selected.
Possible languages are German and English.
How to change the language:
1. Click on Sprache/Language in the Extras menu.
2. Select the required language in the window Sprache/Language.
3. Acknowledge your selection with a click on OK.
The GUI display immediately switches to the selected language.

Adjust settings
Display Inch and Fahrenheit

USi parameters are always stored as metric values. Inch and Fahrenheit values can be
displayed after the metric fields. However, parameters are always entered as metric
values.
The function Display Inch and Fahrenheit is available only if the parameterisation
software is set to English. In the Extras menu the function is then shown under Lan-
guage / Sprache. The menu item functions like a switch. If it is switched on, a check
mark is shown in front of the menu item. If it is switched off, the check mark in front
of the menu item disappears.
How to display inches and Fahrenheit:
ÄÄ In the Extras menu click Display Inch and Fahrenheit.

A check mark is set in front of the menu item.
All tabs then additionally display the corresponding values in inches and Fahrenheit.
How to cancel the display:
ÄÄ Click Display Inch and Fahrenheit again.

The check mark in front of the menu item is removed.
All tabs then display only metric values.

Expertenmodus verwenden
Expanded settings for experts
With the setting options in the Standard tab, most common applications can surely
be detected successfully. However, more complex applications require more complex
setting options. These are provided in the parameterisation software in the tab Ex-
pert mode.
Activate expert mode

The tab Expert mode cannot be called as standard. This is intended to prevent pro-
voking a senseless state of USi safety through uncontrolled parameter changes.
In order to be able to use the expert mode, it must first be activated in the Extras
menu.
How to activate the expert mode:
ÄÄ Click on Activate expert mode in the Extras menu.
The expert mode is activated, the Expert mode tab appears. The menu item is now
called Deactivate expert mode.
How to deactivate the expert mode:
ÄÄ In the Extras menu click Deactivate expert mode.
Expert mode is deactivated, and the Standard tab is displayed. The menu item is
now called Activate expert mode.

Overview of the Expert mode tab

Parameter for sensor 1 and 2 (transducers 1 and 2)
7 direct parameters (incl. hysteresis)
Transmission intensity
Time Variable Gain (TVG)
Typical procedure
Typical procedure:
1. Adapting parameters: objects to be detected
2. Check TVG
3. Check transmission intensity
In step 1 the size of the objects to be detected is analysed.

What is the size of the majority of the objects?
How large is the largest object? How small is the smallest object?

Recommended initial settings:

Size Echo gain Sensitivity
high 3 4
medium 5 5
low 7 8
In step 2 the runtime-dependent gain is checked and determined (see chapter De-
termining the TVG).
In step 3 the transmission intensity is checked and selected (see chapter Select trans-
mission intensity).
Step 2 and step 3 have greater effects on the detection result than step 1. After steps
2 and 3 it is therefore recommended to start the 7 direct entries with the factory set-
tings and to approach the detection situation step for step.
And remember: Changed options or parameters are initially changed in the parame-
terisation software only, but not in USi safety. To transmit the changes to USi safety,
click the Write parameters button.

Echo amplification
Depending on distance, object form and surface of the object, the echoes can be
clearer or weaker. In order to receive usable input signals, it is possible to increase
the incoming (analogue) echo with the parameter Echo amplification. Sometimes
more (up to coefficient 10×), sometimes less (up to coefficient 1×). The parameter
value has no unit and indicates the amplification factor.
The parameter Echo amplification is the hardware-side counterpart to the soft-
ware-side parameter Sensitivity.
Possible parameter values are 1 to 10.
As standard, 5 – medium amplification – is preset.
How to set echo amplification:
1. Enter a new value in the field Echo amplification.

3. Check the result in the Diagnosis tab, if necessary.
USi safety immediately starts to work with the new value for Echo amplification.
CAUTION Functional impairment through increased EMC interference radiation

EMV interference radiation is also increased with echo amplification. In some cir-
cumstances, strong enough for the OSSD outputs to also be stuck in the OFF state.
EMC interference resistance was checked and confirmed with the factory settings.
ÄÄ Try to keep echo amplification as low as possible.
Note: Echo amplification influences TVG. TVG is multiplied with the parame-
ter Echo amplification. The yellow characteristic line TVG in the Diagnosis tab
is applied with precisely this coefficient. I.e. every coefficient <5 moves the yellow
TVG characteristic line down while every coefficient >5 moves it up. Reason: 5 is the
standard setting.

Sensitivity
In addition to the echo amplification, echo evaluation can also be influenced with
the parameter Sensitivity. Unlike the echo amplification, the parameter Sensitivity
does not affect the incoming (analogue) echo signal, but the digitalized echo signal
before the internal detection process. In order to receive usable echo signals, the
threshold value for the “Detection of a change in the detection field” is raised or low-
ered with the parameter Sensitivity. Parameter values >5 raise the threshold value,
parameter values <5 lower the threshold value. The parameter value has no unit and
indicates the sensitivity.
The parameter Sensitivity is the software-side counterpart to the hardware-side pa-
rameter Echo amplification.
As standard, 5 – medium sensitivity – is preset.
How to set the sensitivity:
1. Enter a new value in the field Sensitivity.

USi safety immediately starts to work with the new value for sensitivity.

Multiple scan
With the parameter Multiple scan, you determine the number of required identical
detections until USi safety verifies an object as “newly added” and opens the OSSD
outputs. Low parameter values make USi safety “more sensitive” or “speedy”. High
parameter values make USi safety “more tolerant” or “inactive”.
Multiple scan is the counterpiece to power-up delay. The multiple scan can there-
fore also be called power-off delay.
The parameter Multiple scan directly influences the response time: The higher the
multiple scan, the longer the response time. Per unit of multiple scan, 33 ms can be
anticipated. For simplification purposes, GUI indicates the anticipated response time
in seconds behind the entered parameter value.
The parameter value has no unit and indicates the number of detections.
As standard, 3 is preset.
How to set the multiple scan:
1. Enter the required value in the field Multiple scan.

USi safety immediately starts to work with the new value for multiple scans.

Power-up delay
With the parameter Power-up delay, you determine the number of required iden-
tical detections until USi safety verifies an object that was previously verified as exist-
ent as “removed again” and closes the OSSD outputs. Low parameter values make
USi safety “more sensitive” or “speedy”. High parameter values make USi safety “more
tolerant” or “inactive”.
The power-up delay is the counterpiece to the multiple scan, the power-off delay.
The parameter Power-up delay directly influences the renewed readiness time: The
higher the power-up delay, the longer the renewed readiness time. Per unit of pow-
er-up delay, 33 ms can be anticipated. For simplification purposes, GUI indicates the
anticipated response time in seconds behind the entered parameter value.
Parameter values below 30 can be useful if a PLC is connected downstream.
The parameter value has no unit and indicates the number of detections.
How to set the power-up delay:
1. Enter a new value in the field Power-up delay.

USi safety immediately starts to work with the new value for power-up delay.

Near field up to
A near field describes that sensor-close area of the detection field that is protected
against possible overmodulation of the echo signal by reducing echo amplification.
The parameter Near field up to thus indicates the distance up to which to the re-
duced echo amplification applies. The parameterised echo amplification is applied to
any distance that is higher than the specified parameter value Near field up to.
The parameter Near field up to can be used to minimise influencing factors due to
the installation of the sensor (transducer).
The parameter value is provided in whole-cm steps.

How to set the near field:
1. Enter the required value in the field Near field up to.

USi safety immediately starts to work with the new value for the near field.

Echo broadening starting at

The parameter Echo broadening starting at specifies the distance from which the
echo envelope curve is broadened in the USi safety-internal signal processing. Any
distance that is higher than the specified parameter value Echo broadening start-
ing at, is applied with the echo broadening. The broadening factor itself is specified
internally and cannot be changed. The echo broadening helps to detect reliably even
smaller objects at larger distances.
Possible parameter values are 15 to 250 (= maximum measuring distance).
How to set the power-up delay:
1. Enter a new value in the field Echo broadening starting at.

USi safety immediately starts to work with the new value for echo broadening.

Hysteresis
A special feature of USi safety is its high repeating precision. USi safety thus works
quasi without hysteresis. That means that the predefined switching points are ad-
hered to exactly. With the approach as well as the moving away of the same object.
In some application cases, however, hysteresis is readily used as a type of tolerance
range. With a sensor without hysteresis, such as e.g. USi safety, this is not possible.
The function “Hysteresis” was therefore specially implemented in USi safety. This
function is activated by entering the Hysteresis parameter value for switch point SP1
only. Exceptions:
•• If the parameter value is 0 (zero), then the function “Hysteresis” is deactivated.
•• If the switching points SP1 and SP2 are identical, then the function “Hysteresis” is
deactivated, also if the parameter value is greater than 0 (zero).
In the protection field (SP1) the Hysteresis parameter value causes delayed switching
of the OSSD safety outputs to an ON state when removed. There is no plus-minus
hysteresis here. The Hysteresis parameter value has no effect on the warning field
(SP2). Switch point SP2 switches without a hysteresis both during approach and
removal. Activation of the function “Hysteresis” results in the following hysteresis im-
age:

Possible parameter values are
0 to SP1/10, if SP1/10 < (SP2 - SP1), or
0 to (SP2 - SP1), if (SP2 - SP1) < SP1/10.
How to set the hysteresis:
1. Enter a new value in the field Hysteresis.

USi safety immediately starts to work with the new value for hysteresis.

Determining the TVG

TVG stands for Time Variable Gain and means the runtime-dependant gain. TVG
compensates the damping factor that is typical for the medium air.
TVG1 TVG2
with initial gain without initial gain
high sensitivity, even in the immediate high sensitivity, except in the vicinity of
vicinity of the sensor the sensor, in order to prevent possible
overmodulation there
As standard, TVG1 is preset.
How to set TVG:
1. Select the option TVG1 or TVG2 in the group field Time Variable Gain.
USi safety immediately starts to work with the new specification for TVG.

Select transmission intensity

The “volume” of the transmission burst is determined with the selection in the group
field Transmission intensity. The louder, the clearer the echo. For the highest
performance, transmission intensity is therefore preset to maximum. A must for
applications with a softer environment (panels in a textile setting), sometimes coun-
terproductive in harder environments (steel shelf with steel containers) though. The
selection of the transmission intensity can be crucial here.
The transmission intensity directly affects the geometry of the sonic lobe: The smaller
the transmission intensity, the narrower the sonic lobe.
Steps: maximum – high - medium - low
Maximum is preset as standard.
How to select the transmission intensity:
1. Click first on Single echo or Fixed echo in the Diagnosis tab.

Does USi safety seem to detect more objects than you do with the naked eye? Is the
oscillogram unusually “jittery”?
2. Click on Continuous echo again to stop the continuous echo.
3. Switch to the Expert mode tab.
4. Select the option high in the group field Transmission intensity.

6. Switch to the Diagnosis tab.
7. Click on Single echo or Fixed echo.
8. If the displayed oscillogram is clearly “less jittery” then you are finished.
9. If the oscillogram is nearly the same, repeat the procedure starting at step 2 and
select the next-lower transmission intensity.
CAUTION Hazard to hearing through high sound pressure

With the settings medium and low, the transmission burst is hardly noticeable.
However, USi safety continues to transmit with high sound pressure.
ÄÄ Keep a sufficient distance (> 50 cm) to the sensors.

The selection of the transmission intensity can also be used to reduce the acoustic
load: the lower the transmission intensity, the lower the sound pressure level (SPL).
The safe function of the protective device should always have priority though.
Transmission intensity Sound pressure level (SPL)*

maximal 132 dB
high 130 dB
medium 126 dB
low 122 dB
* on the reference axis at 1 m distance

Setting temperature compensation

The speed of sound in air is a constant that depends greatly on the temperature. For
correct results, the prevailing air temperature must always be taken into considera-
tion (see Chapter Considering the temperature).
In closed rooms, the air temperature is relatively consistent. It is enough here to set
the temperature once. USi safety is preset to a constant temperature value of +18 °C
as standard. That complies with the average anticipated temperature in the industrial
field.
In areas with highly fluctuating temperatures, the repeating precision is impaired. Au-
tomatic temperature compensation (external NTC) is pre-destined for this case: The
temperature currently prevailing on the sensor (ultrasonic transducer) is measured
continuously and the temperature compensation set appropriately. You are thus al-
ways on the safe side even with highly fluctuating temperatures.
Possible parameters are -30 to 50 [°C]. In the positive area of the temperature scale,
the plus sign is omitted.
As standard, the constant +18 °C is preset.
How to set the temperature compensation:
1. In the Temperature compensation group box enter a new temperature value

in degrees Celsius in the °C field.
USi safety immediately starts to work with the new specification for temperature
compensation.
How to activate automatic temperature compensation:
1. Click on extern NTC in the group field Temperature compensation.
USi safety immediately starts to work with automatic temperature compensation.
If you work with a reference object and constant temperature compensation,

then the reference object can “wander away” from its position because of a strong
temperature drift. USi safety then expects the reference object at another position.
The current detection image no longer matches the reference image, USi safety de-
tects this and switches the safe outputs OSSD off.

Setting reciprocal interference suppression

If multiple sources of ultrasonic waves are used in one area, they can influence each
other. In the worst case, reciprocal interference occurs between two automated
guided vehicles (AGVs) when they meet. Technical measures are available to prevent
reciprocal interference. In the case of USi safety, interference suppression is achieved
by means of a complex software algorithm that is reflected in the duration of the
measurement cycle.
Reciprocal interference Measurement cycle, Measurement cycle,

suppression typical maximum
off 33 ms –
medium 44 ms 58 ms
high 50 ms 71 ms
The time data next to the fields

•• Restart delay (in Standard tab),
•• Multiple scan (in Expert mode tab) and
•• Power-on delay (in Expert mode tab)
is adjusted automatically.
Disabling reciprocal interference suppression

There are two cases where reciprocal interference suppression is not necessary:
•• If only one USi safety is used in the monitored area.
•• If multiple USi safety units are used in the monitored area, but the sonic lobes do
not overlap and their echoes cannot cause reciprocal interference.
In these cases, reciprocal interference suppression should be disabled to achieve a
shorter measurement cycle.
Possible parameter values are off, medium and high.

The default value is off.
How to set the interference suppression:
1. In the group box Reciprocal interference suppression select the option off,
medium or high.
-- off: no suppression of reciprocal interference
-- medium: medium suppression of reciprocal interference
-- high: high suppression of reciprocal interference
2. Click on Write parameters.
3. Check the result in the Diagnosis tab.
4. Carry out the release test (see chapter Release).
USi safety immediately starts using the new value for the reciprocal interference sup-
pression.

Checking the detection field
Different parameters were changed and transferred to USi safety. Now you want to
be able to evaluate the new settings before you carry out release test repeatedly?
Or an already released USi safety suddenly seems to detect unexplainable things and
you would like to see what the USi safety “sees”?
Fast and result-oriented support is provided by the parameterisation software in the

Diagnosis tab. Here you can
•• view the echo signals in oscillograms
•• read out the detected distances in the numerical display
•• display the reference image
•• show the difference to the reference image
•• carry out renewed teach in
•• display and hide individual curves
The full scope of the Diagnosis tab is available in both log-in levels – level 1 and lev-
el 2.

Overview of the Diagnosis tab
Oscillogram, characteristic curve selection and distance display for sensor 1

(transducer 1)
Selection of oscillogram for sensor 1 and 2 (transducers 1 and 2):
Echo, teach reference and teach difference.
Buttons for single echo, fixed echo and teach in.
Oscillogram, characteristic curve selection and distance display for sensor 2
(transducer 2)
Depending on the selection in the group field Oscillogram selection, up to three

characteristic curves are marked with different colours in the oscillograms.
Blue: Echo
Red: Echo digital, teach reference or teach difference
Yellow: TVG (standard: hidden)
The individual characteristic curves can be displayed or hidden with the check box
behind the legend.

Teach in: Teaching the environment in again

Has an environment that is to be viewed “as given” changed since the last teach in?
Was the position of the sensor (ultrasonic transducer) changed?
Minimal changes can already have a great impact. Therefore finish every change,
however small, with a renewed teach in.
How to teach in the environment again:
1. Make sure that there is nothing in the detection field that normally does not be-
long there (including you and your limbs).
2. Click on Teach in echo in the Diagnosis tab.

Wait until the teach in is completed.
3. Check the result: Generate oscillograms of the type Echo.

The teach in was successful if all peaks are without a red border.
Generating oscillograms
The parameterisation software offers two options to generate oscillograms:
Single echo and fixed echo.
Single echo Fixed echo

What for? • Quick check after • “Live” check of the de-
teach in tection field
• Detailed observation • Dynamic observation
“at rest”
• Distance display
Start Button Single echo Button Fixed echo
Oscillogram type static dynamic
(snapshot) (“Live” image)
Distance display static dynamic
End automatic Button Fixed echo
The oscillogram shows the same static image image displayed last
Whether it is single echo or fixed echo, both can be executed in parallel to normal
operation without influencing the protective function of USi safety.

Preselection for the oscillogram

Before you generate an oscillogram, you have the choice between
•• Echo
•• Teach reference
•• Teach difference
With the preselection, you determine what is to be displayed in the oscillogram with
the red characteristic line. Yellow characteristic line: Time Variable Gain (TVG).
Echo is preset as standard.
Shows - next to the blue characteristic line (Echo) - the digitalized and evaluated
echo (Echo digital) as a red characteristic line.
Shows - next the blue characteristic line (Echo) - the reference image recorded
through a teach in as a red characteristic line.
Shows - next the blue characteristic line (Echo) - the difference to the recorded refer-
ence image as a red characteristic line.

Interpreting oscillograms
Whether it is a static single echo or a dynamic fixed echo, the oscillogram delivers
easily interpreted diagrams for the invisible detection field.
The blue characteristic line shows the analogue incoming echo signals depending on
their signal strength (Y axis) and distance (X axis) at which they were reflected.
The yellow characteristic line shows the currently set TVG characteristic line depend-
ing on its thickness (Y axis) at a specific distance (X axis). It changes its appearance
only during the switch from TVG1 to TVG2 and if the parameter Echo amplification
(in the expert mode) is changed.
The red characteristic line shows the evaluated and digitalized echo. If the analogue
echo signal exceeds a preset level, USi safety rates this as a detected object and enve-
lopes this peak with a rectangular curve.
The following example is to train you to the extent that you can clearly evaluate your
special application case and unerringly find the optimal setting.
Example 1:
Empty detection field
The oscillogram should look like this if the detection field is empty. The plateau
on the left edge shows the normal oscillation of the sensor (ultrasonic transducer).
Smaller peaks at are insignificant reflections that are caused e.g. by uneven surfac-
es. With the standard setting, such minimal reflections are ignored by USi safety. This
shows you that the red characteristic line (Echo digital) does not envelope the peaks.
Example 2:
Object detected
The plateau on the left edge shows the normal oscillation of the sensor (ultrasonic
transducer). The high peak at approx. 80 cm distance shows a clear echo. The red
characteristic line (Echo digital) envelopes the blue characteristic line (echo) at this
position. That indicates that USi safety rates the analogue echo at this position as a
detected object. The small peak at is an insignificant reflection.

Example 3:
Object taught in as ref-
erence object
transducer). The small peak at is an insignificant reflection. The high peak at
about 210 cm distance shows a reference object that is accepted as given after the
teach in. Unlike with “Object detected”, the peak of the blue characteristic line (Echo)
here is not enveloped by the red characteristic line (Echo digital).
Example 4:
Detection field empty,
reference object missing
transducer). The empty red envelope curve at indicates that the reference object is
missing. An empty red envelope curve generally indicates that a taught in object is no
longer in the same place or no longer has the same alignment to the sensor as it did
at the time of the teach in.
Example 5:
one object detected, ref-
erence object missing
transducer). The high peak at is enveloped by a red characteristic line (Echo digital).
This indicates that USi safety has detected an object. The small peak at is an insig-
nificant reflection. The empty red envelope curve at indicates that the reference
object is not detected. Reason: The reference object is either covered by the object
detected at or it is no longer in the same place or no longer has the same align-
ment to the sensor as it did at the time of the teach in.

Identifying and eliminating faults
Troubleshooting and remedies
Prerequisite: The evaluation unit is connected to the supply voltage. There is at least
one sensor connected. Only taught-in objects are located in the detection field.
Tip: The Chapter Relationships lists possible LED displays and their significance.
Fault display Possible cause Elimination

Green LED „POWER“ is off No or incorrect supply voltage 1. Check the supply voltage: Does it com-
ply with the type plate?
2. Check the terminal assignment: cor-
rectly connected?
If supply voltage is correctly connected: ÄÄ Replace the evaluation unit
Evaluation unit faulty
Yellow LED „Warning“ Sensor (ultrasonic transducer) soiled ÄÄ Check the active surface of the sensor:
flashes Clean and empty?
with clean and empty active surface: Sen- ÄÄ Replace the sensor
sor (ultrasonic transducer) defective
Yellow LED “Warning” is new parameter were written but no re- 1. Connect the evaluation unit with the
lit permanently lease test carried out parameterisation software
2. Perform a release test
Occasional switching of EMC noise source in the immediate vicinity 1. Check the cabling between sensor
the outputs for no appar- of the sensor or its cable and evaluation unit: Too close to noise
ent reasons sources?
2. Shield evaluation unit, sensors and
their cables against electromagnetic
noise sources
Temperature striations within the detection ÄÄ Check the detection field: Are there
field heat or cold sources?
occasional compressed air blasts ÄÄ Check the environment: Compressed
air noises in the direction of the detec-
tion field?
Transverse reflections or reflections due to ÄÄ Activate reciprocal interference sup-
overreach pression
The oscillogram (Diag- Shielding on the device cable is connected ÄÄ Cut off the stripped shielding of the
nosis tab) shows clearly device cable
increased ambient noise no PELV circuit used ÄÄ Wire the voltage supply into a PELV
or circuit
yellow LED “Warning”
flickers


Red LED „Fault“ is on Round connectors have loose contacts ÄÄ Tighten the nuts of the round connec-
tors
USi safety is in error mode 1. Connect the evaluation unit with the
parameterisation software
2. Wait for the reaction after the log in:
Useful note?
3. Disconnect the supply voltage for at
least 5 s
USi safety still stays in error mode: internal 1. In the Extras menu click Read fault sta-
error tus to receive information about the
fault
2. In the Extras menu click Info to Mayser
to receive direct help
3. Replace the evaluation unit
The oscillogram shows Sensor is severely jammed ÄÄ Check the installation position of the
extended oscillation sensor: (Clamping) forces may act on
the O-rings only
Sensor is slightly jammed ÄÄ If possible, increase the parameter val-
ue in Near field up to
Yellow LED „OUT X“ (nor- Taught-in detection field has changed ÄÄ Perform a release test
mally open contact) is The reference object was removed 1. Position the reference object again
on, although there is no
variable object in the de- 2. Perform a release test
tection field
Yellow LED „OUT X“ (nor- The objects are actually outside of the de- ÄÄ Observe the maximum measurement
mally open contact) is off, tection field distance of 250 cm
although objects in the
ÄÄ Observe the exit angle of the sonic
detection field are appar-
lobe: ±17° and ±5°
ently changing
Switch points are incorrectly defined ÄÄ Reset the switching points
No signal at output Output connections have been switched ÄÄ Check the lead colours on the unit ca-
ble
ÄÄ Wire the outputs correctly
The object is not detect- The object is outside of the detection field ÄÄ Check the limits of the detection field
ed with a test object
Object has sound-absorbing structure ÄÄ Check the acoustic quality of the object
ÄÄ Rethink the position of the sensor
Object with sound-dividing shape; sound is ÄÄ Check the acoustic quality of the object
deflected
Transmission intensity setting is too weak ÄÄ Increase the transmission intensity
Exchange air for a different medium or ÄÄ Check the entire sound path to the
vacuum object: Is there air available along the
entire path as transmission medium?


Static object is some- The object is on the boundary of the detec- ÄÄ Change the corresponding switch
times detected, some- tion field point
times not detected
ÄÄ Reconfigure the sensor
Object has sound-absorbing structure ÄÄ Check the acoustic quality of the object
Object with sound-dividing shape; sound is ÄÄ Check the acoustic quality of the object
deflected
Parameters are set at threshold values ÄÄ Check the parameters
ÄÄ Check the settings for transmission in-
tensity and TVG
Occasional false activa- Sources of acoustic interference (e.g. es- 1. Remove the source of interference
tion caping compressed air)
2. Shield the sensors from the sources of
acoustic interference
3. Reconfigure the sensor
Acoustic transverse reflections from other 1. Activate reciprocal interference sup-
ultrasonic sources pression
Reflections due to overreach of the sensor 1. Activate reciprocal interference sup-
pression
Reciprocal interference from sensors 1. Activate reciprocal interference sup-
pression
Electromagnetic interference 1. Check the cable laying between the
sensor and the evaluation unit: Too
close to the source of interference?
2. Shield evaluation unit, sensors and
their cables against electromagnetic
noise sources
Too extreme temperature fluctuations ÄÄ Give the USi safety sufficient time
within too short a time period (> 10 min) to acclimatise.
The fault can still not be removed?
ÄÄ Contact Mayser support: Phone +49 731 2061-0.
ÄÄ Use the Info to Mayser function in the Extras menu.
ÄÄ In case of queries, have the data on the type plate at hand.

Accessories
Replacement parts
Designation Part number
Screw plugs for evaluation unit 1005377
Protective cap for M8 connection E2003392

on evaluation unit
Sensor (ultrasonic transducer)

ps/mt/18 × 4/m
with 1.5 m cable 1005264

O-ring set 18 × 2.5 mm O-Ring Set 7502819

18 × 2.5 mm for sensor (ultrasonic
transducer), to mount
in standard mounting brackets
(clamping version), consisting of:
2× O-ring 18.0 × 2.5 mm
O-ring set 17.5 × 2 mm for sensor 7502820

(ultrasonic transducer), to mount in
optimised mounting brackets (inte-
grated version), consisting of:
2× O-ring 17.5 × 2.0 mm
Parameterisation software for USi 7503630

safety
on USB stick
CAUTION Overall safety endangered

If parts of the product are not replaced with original parts from Mayser, operation
of the protective device may be impaired.
ÄÄ Only use original parts from Mayser.

Accessories
Accessories
Designation Part number

Sensor (ultrasonic transducer) in
M30 housing

Enclosure set, horizontal for sensor, 7503916

including cable bushing, consisting
of:
1× Enclosure horizontal, 2 parts
2× O-ring 17.5 × 2.0 mm
2× Screws M5×12
2× Screws M3×8
Enclosure set, vertical for sensor, in- 7503917
cluding cable bushing, consisting of:
1× Enclosure vertical, 2 parts
2× O-ring 17.5 × 2.0 mm
2× Screws M5×16
2× Screws M3×10
Extension cable only for sensors 1005903

with 1.5 m cable, cut-to-size includ-
ing M8 socket and M8 plug
Length: 1.5 m
Unit cable M12 × 8 / USi, 1005433

cut-to-size incl. lead ferrules and
ready-to-connect shielding braid
Length: 2 m
Temperature sensor with mounting 1006566

tab, for evaluation unit, cut-to-size
with 1.5 m cable and 6-pin M8 plug
CAUTION Overall safety endangered

Malfunctions can occur if third-party replacement parts are installed instead of orig-
inal parts from Mayser.
ÄÄ Only use original parts from Mayser.

Maintenance and cleaning
Maintenance and cleaning
Maintenance
USi safety is maintenance-free for the most part.
ÄÄ Check the protective device daily for manipulation if you let USi safety work with-
out a reference object.
ÄÄ Repeat the release monthly.

Check also downstream warning devices.
ÄÄ Replace the O-rings at the latest after 5 years.
ÄÄ Replace the sensors at the latest after 10 years.
Cleaning
ÄÄ Disconnect all devices and live parts in the immediate environment of the pow-
er supply and protect them against being switched on again (see relevant oper-
ating instructions).
ÄÄ Check that all devices and parts are disconnected from the power supply.
ÄÄ Clean the outside of the enclosure with a dry cloth.

Decommissioning
Decommissioning
WARNING Danger of injury due to electrocution!

If the wiring is detached while the evaluation unit is still connected to the supply
voltage, current can flow to 1 A.
ÄÄ It is imperative to follow the sequence of instructions.
1. Remove the supply voltage.
2. Disconnect the wiring.
Disposal
The devices produced by Mayser are professional electronic tools exclusively intend-
ed for commercial use (so-called B2B devices). Unlike devices mainly used in private
households (B2C), they may not be disposed of at the collection centres of public sec-
tor disposal organisations (e.g. municipal recycling depots). At the end of their useful
life, the devices may be returned to us for disposal.
WEEE reg. no. DE 39141253

Conformity
Conformity
The design type of the product complies with the basic requirements of the following
directives:
•• 2006/42/EC (Safety of machinery)
•• 2011/65/EC (RoHS)
•• 2014/30/EC (EMC)
The Declaration of Conformity is available in the download section of the website:

www.mayser.com/en/downloads
EC design test
The product was tested by an independent institute.
An EC design type test certificate confirms conformity.
The EC design type test certificate is available in the download section of the website:
www.mayser.com/en/downloads

Factory settings
Factory settings
The function Reset parameters to standard resets USi safety to the delivery condi-
tion. The factory settings saved in USi safety hereby overwrite all current parameters.
The standard values apply respectively for sensor 1 and sensor 2.
Display tab Parameter Standard value

Standard Protection field range normal
Protection field 200 [cm]
Warning field 200 [cm]
Signal output OUT high active (Normally
open contact)
Protection field testing with
Restart delay 0 [Measurement cycles ]
Expert mode Echo gain 5 [–]
Sensitivity 5 [–]
Multiple scan 3 [–]
Power-on delay 30 [–]
Close range to 1 [cm]
Echo distribution from 50 [cm]
Hysteresis 0 [cm]
Transmitting intensity maximum
Time Variable Gain TVG1
Temperature compensation constant +18 °C
Reciprocal interference suppres- off
sion
Diagnosis Graph line echo activated
Graph line echo digital activated
Graph line teach reference hidden
Graph line teach difference hidden
Graph line TVG deactivated
Select oscillogram Echo

Technical data
Technical data
The “typ.” information refers to USi safety in the delivery condition. If parameters are
changed, these values change. The then possible range is specified in brackets with
the “up to” information.
USi safety
Testing basis IEC 60204‑1, IEC 60947‑5‑2,
IEC 61326‑3‑1*, ISO 13849
Connecting voltage US
Nominal voltage PELV: DC 24 V
Voltage tolerance DC 21 to 28 V
Rated current 150 mA
External protection 2 A time-lag
Power consumption < 3.6 W
Times
Reaction time ta typ. 100 ms (33 to 3300 ms)
Re-start time tw typ. 330 ms (33 to 3300 ms)
Safety classifications
ISO 13849-1:2015 Category 3 PL d
MTTFD 316 a
DCavg 87 %
CCF Anforderungen erreicht
interference transmission in compliance IEC/CISPR 11 Group 1, Class A
with
Detection functions
Measurement method Ultrasonic pulse-echo procedure
Sound frequency typ. 103 kHz
Sound level pressure (max.) typ. 132 dB SPL at 1 m
Measurement frequency 30 Hz
Measurement distance (max.) typ. 200 cm (1 to 250 cm)
Blind zone 1 cm
Opening angle sonic lobe (see chapter Sonic lobe)
horizontal ±17°
vertical ±5°
Resolution 1 cm
Object detection
Size (min.) typ. Ø 1 cm
Speed, axial (max.) typ. 2 m/s (to 2.5 m/s)
Repeatability ±0 cm
Hysteresis typ. 0 cm (0 to SP1/10)
Temperature compensation
with automatic/manual
without = Temperature drift 0.17 %/K
* With sensor (ultrasonic transducer) 1005264 or 1006878 the USi safety deviates from evaluation crite-
rion A in the range from 100 kHz to 170 kHz: instead of exhibiting normal operating behaviour, the USi
safety switches to fail-safe mode.

Technical data
USi safety
Inputs
Sensor 1 and 2 U1 and U2
Connection M8, 3-pole
Line length 1.5 m or 3.0 m
Temperature sensor X2
Connection M8, 6-pole
Line length 1.5 m
USB
Version 2.0
Type USB mini-B
Outputs
Unit cable X1
Connection M12, 8-pole, min. 0.25 mm2
Line length (max.) 30 m
Safe outputs OSSD NC contact, Power FET PNP
Safe output OSSD 1.1 Pin 1
switching current (max.) 150 mA per output
switching voltage (max.) US
Signal outputs OUT NO contact, Power FET PNP
Signal output OUT 1 Pin 6
Signal output OUT 2 Pin 8
Switching current (max.) 150 mA per output
Switching voltage (max.) US
Mechanical operating conditions

Material, enclosure
Evaluation unit Aluminium die casting
Sensor PA 6.6, PBT
IEC 60529: Degree of protection
Evaluation unit IP65
Sensor IP69
ISO 20653: Degree of protection
Evaluation unit IP65
Sensor IP69K
max. humidity (23 °C) 99 %
Operating temperature -10 to +50 °C
Storage temperature -40 to +85 °C
Dimensions (B × H × T)
Evaluation unit 125 × 91 × 41 mm
Sensor 12.6 × 26.6 × 21 mm
Weight
Evaluation unit 450 g
Sensor (incl. cable) 25 g

Flow charts
Flow chart
Start

Flow charts
Detection

Flow charts
Parameterising

Glossary
Glossary
Italicized words, e.g. delivery condition, are terms that are also defined in this glossary.
Active Surface Surface of a proximity switch, from which ultrasound is emitted and enters.
[IEC 60947‑5‑2, 2.2.11.2]
AGV Abbreviation for Automated Guided Vehicle. English equivalent of the German ab-
breviation for Driverless Transport System (FTS).
Blind zone Zone between the active surface and the minimum switching distance, where no ob-
ject can be detected. [IEC 60947‑5‑2, 2.3.1.3]
Blind zone of the USi safety: 1 cm.
Coverage range Range, where the switch points can be set. [IEC 60947‑5‑2, 2.3.1.2]
Delivery condition State of USi safety when it leaves Mayser. All parameters comply with the factory set-
tings.
Detection Basic function of a proximity switch. The evaluation of the echo signals knows only
the two states “object existing” and “object not existing”.
Detection field The area within the sound beam that is monitored by USi safety – Protection field and
warning field. The detection field is limited axially by the switching points and laterally
as well as in the vertical alignment by the edges of the sound beam. (Cf. Detection
range, sound beam)
Diagnosis A tab in the parameterisation software, in which possible problems in the detection
field are visualised with the help of oscillogram and Distance display. The goal is fast
and result-oriented trouble-shooting. (Cf. Expert mode, Standard)
Distance (a) The space between two points. First point of the USi safety is the active surface,
second point is the detected object. (cf. Measurement distance)
(b) Numerical display in the Diagnosis tab of the parameterisation software. The dis-
play shows the distance to a detected object in centimetres.
Echo (a) Returning (ultra)sonic wave.

(b) Standard option in the group field Oscillogram selection in the Diagnosis tab of the
parameterisation software with which the illustration of the oscillogram is defined:
The analogue echo signal (blue) as well as the digital echo (red) are displayed.
Echo amplification Parameter value in the Expert mode tab of the parameterisation software that increas-
es the incoming echo signals as a coefficient. Possible parameter values are 1 to 10. In
the delivery condition, the parameter value Echo broadening is preset to 5.
Echo amplitude measurement Complex measurement procedure of the USi safety, where the measurement path
itself is evaluated. This measurement procedure provides greater safety against dis-
ruptive signals. (Cf. Echo runtime measurement, measurement procedure)

Glossary
Echo broadening starting at Parameter value in the Expert mode tab of the parameterisation software that defines
the distance at which the echo envelope curve is subsequently broadened in order to
be able to better detect small objects at larger distances. Possible parameter values
are 15 to SP2. In the delivery condition, the parameter value Echo broadening starting
at is preset to 50 [cm].
Echo digital Red characteristic curve in the Oscillograms of the Diagnosis tab. It displays the digital
echo parallel to the analog echo signal (blue).
Echo envelope curve Interim result of the internal signal processing. The echo envelope curve serves as a
basis for the internal evaluation of the echo signals.
Echo evaluation Internal processing of the incoming echo signals.
Echo runtime measurement Ultrasonic measurement procedure, where the time span between the transmitting
pulse and the input of the echo signal is used as the basis for the evaluation of the
distance. (Cf. Echo amplitude measurement, measurement procedure)
Echo signal Signal, which generates an echo on the active surface. (Cf. Continuous echo, echo)
Evaluation unit The part of the USi safety that controls the sensor, processes incoming signals from
the sensors and supplying them to the outputs as evaluated signals.
Expert mode A tab of the parameterisation software in which experts can specifically adjust the
analysis of the echo signals for complex tasks. They can enter definite parameter
values, select default values like e.g. object detection and, depending on the require-
ment, use aids like e.g. temperature compensation. (Cf. Diagnosis, Standard)
Factory settings Table with all parameters that are saved permanently in USi safety. The function
“Reset parameters to standard” overwrites all parameters with the data saved in this
table. In the delivery condition, all parameters comply with the factory settings.
Fixed echo Function in the Diagnosis tab of the parameterisation software. A click on the button
Fixed echo induces the parameterisation software to show the incoming echo signals
“live” in an oscillogram. The continuous display can be stopped by clicking the Con-
tinuous echo button.
(Cf. Single echo)
Group field Smallest logical unit in a tab of the parameterisation software, such as e.g. the group
field “Signal outputs OUT” with the two radio buttons “High active (NO contact)” and
“Low active (NC contact)“. (Cf. Tab)
GUI Abbreviation of Graphical User Interface. Graphical user interface of the parameteri-
sation software.
Hysteresis Parameter value in the Expert mode tab of the parameterisation software that assigns
a specific tolerance to the switching point SP1.
During an approach, the object is detected as “existing” at “SP1 – hysteresis”, with a
distance as “not existing” at “SP1 + hysteresis”.
Possible parameter values are integers in centimetres from 0 to SP1/10, if SP1/10 <

Glossary
(SP2 - SP1), or from 0 to (SP2 - SP1), if (S2 - SP1) < SP1/10. In the delivery condition,
the parameter value Hysteresis is preset to 0.
Initialisation Start sequence of the USi safety as soon as the supply voltage is connected. During in-
itialisation testing is conducted for, among others, the internal hardware, the stored
functional parameters, the connected sensors and the outputs. The result of the test
is stored internally in the diagnosis memory. If the diagnosis memory does not con-
tain any error reports, the USi safety immediately starts its function.
Logoff sensor Function of the USi safety, to log off and disconnect the connected sensor 2 from the
USi safety.
Logon sensor Function of the USi safety, to connect sensor 2 and log on to the USi safety.
Measurement cycle Period between two transmission bursts during which USi safety processes a com-
plete measurement routine: sending a transmission burst, processing incoming echo
signals, evaluating processes signals and, if necessary, changing the state of the out-
puts.
Measurement distance Distance between active surface and detected object. The minimum measurement
distance is equal to the minimum switching distance, the maximum measurement
distance is equal to the monitoring range.
Measurement frequency Number of measurement cycles of USi safety in one second (typ. 30 Hz). The meas-
uring frequency is influenced significantly by the number of sensors as well as the
switching point SP2. (Cf. Sound frequency)
Measurement object Specified part, which is used for comparative measurements of the switch points and
the detection fields. Synonymous with Reference object. (Cf. Object)
Measurement procedure Procedure to determine a physical size. There are two measurement procedures for
USi safety: Echo runtime measurement and echo amplitude measurement.
Minimum switching distance Lower limit of the specified coverage range of an ultrasonic proximity switch.
[IEC 60947‑5‑2, 2.3.1.2.1] (Cf. smin)
Monitoring range Maximum measurement distance within a defined detection field of an ultrasonic
proximity switch.
Multiple scan Parameter value in the Expert mode tab of the parameterisation software which de-
fines how often an object must be detected as “existing” to cause a signal change at
the outputs. The multiple scan is the counterpiece to the power-up delay. Possible
parameter values are 3 to 20. In the delivery condition, the parameter value Multiple
scan is preset to 3. (Cf. Power-up delay)
NC contact Output with NC contact function that causes the load current not to flow if the meas-
urement object is detected and to flow if the measurement object is detected. (Cf.
output, OSSD, OUT)
Near field up to Parameter value in the Expert mode tab of the parameterisation software that spec-

Glossary
ifies the distance up to which the echo amplification is to be reduced so that echo
signal is not overmodulated in the sensor-close detection field. Possible parameter
values are 1 to 100 [cm]. In the delivery condition, the parameter value Near field up
to is preset to 1 [cm].
Noise interference General side-effect of ultrasound sensor systems. Ultrasonic waves are not audible
to humans. The transmission burst of the sensor (ultrasonic transducer), however, is
perceived as a clearly audible crackle. At a typical frequency of 33 Hz, this may be
perceived as annoying in the long term. Animals may occasionally also hear the ultra-
sonic waves and be annoyed by them.
Normally open contact Output with NO contact function, which effects the flow of the load current when the
measurement object is detected and causes the load current to stop flowing when
the measurement object is not detected. (Cf. Output, OUT)
Object Element, which is detected by the ultrasonic proximity switch in the detection field.
(Cf. Secondary object)
Opening angle Total angle around the reference axis of an ultrasonic proximity switch, where the
sound level is reduced by 3 dB. [IEC 60947‑5‑2, 2.3.1.4] (Cf. Reference axis)
Open parameters Function in the File menu of the parameterisation software that loads already saved
parameters in the GUI again. (Cf. Save parameters)
Operating mode 1 range Operating mode with which the switching point 1 is identical to switching point 2
The detection field extends into 1 area from the minimum switching distance to
switching point 2. In the operating mode 1 range, there is only one protection field,
no warning field.
Operating mode 2 ranges Operating mode with which the detection field is divided into 2 areas.
Area 1: The detection field close to the sensor, also called protection field, extends
from the minimum switching distance to switching point 1.
Area 2: The detection field far from the sensor, also called warning field, extends from
switching point 1 to switching point 2.
Oscillogram Graphical illustration of the entire measuring distance in the Diagnosis tab of the
parameterisation software. The X-Y graph shows the distance in the X direction and
the strength of the received echo signal in the in Y direction. Peaks in the form of sky-
scrapers that are framed by a rectangle indicate detected objects.
OSSD Short name for a safe output switching element (Output Signal Switching Device).
USi safety has 2 safe outputs per sensor. Those are OSSD 1.1 and OSSD 1.2 for sensor
1, OSSD 2.1 and OSSD 2.2 for sensor 2. The safe output OSSD is always applied as NC
contact. (Cf. Output, OUT)
Output Connection at which the output signal of a proximity switch is applied. USi safety has
6 semiconductor outputs, 3 each for every sensor (sensor 1, sensor 2). Every safe out-
put OSSD is an NC contact. Every signal output OUT can be selected as “NO contact”

Glossary
or “NC contact”. In the delivery condition, the signal outputs are preset as “NO con-
tacts”. The signal outputs are defined with the parameterisation software. (cf. OUT)
OUT Short name for signal output. USi safety has 1 signal output per sensor. That is OUT 1
for sensor 1 and OUT 2 for sensor 2. The signal output OUT can be set as NO contact
or NC contact. In the delivery condition, the signal outputs are preset as “high active
(NO contacts)”. (Cf. Output, Signal output, OSSD)
Parameterisation software Software with which all USi safety parameters can be changed in a GUI (graphical
user interface) and transmitted to USi safety via USB interface.
Parameter value Characteristic variable of USi safety that can be changed with the parameterisation
software.
PNP Transistor output Type PNP.
Power-on start interlock Function that prevents USi safety from immediately releasing the safe outputs OSSD
after a restart. A protection field test must first be completed successfully. USi safety
then releases the safe outputs OSSD.
Power-up delay Parameter value in the Expert mode tab of the parameterisation software which de-
fines how often a previously existing object must be detected as “not existing” to
reset the outputs. The power-up delay is the counterpiece to the multiple scan. Pos-
sible parameter values are 10 to 100. In the delivery condition, the parameter value
Power-up delay is preset to 30. (Cf. Multiple scan)
Protection field testing Short function test during which an object must be detected in the second half of the
protection field. (Cf. Power-on start interlock)
Protection field The sensor-distant area of the detection field. A change in the protection field affects
the safe outputs OSSD and the signal outputs OUT. (Cf. warning field)
Proximity switch Position switch, which is activated without mechanical contact with the moving ob-
ject. [IEC 60947‑5‑2, 2.1.1] (Cf. Ultrasonic proximity switch)
Read parameters Function in the tabs Standard and Expert mode of the parameterisation software that
reads out all parameters of the operational USi safety and makes them visible on the
GUI. (Cf. Write parameters)
Real switching distance Switching distance of an individual proximity switch, which is measured at specific
temperature, voltage and installation conditions. [IEC 60947‑5‑2, 2.3.1.5]
Reference axis Axis, which runs perpendicularly to the active surface and through its centre.
[IEC 60947‑5‑2, 2.2.2.1] (Cf. Opening angle)
Reference image Internally saved oscillogram image after a teach in that is considered to be a refer-
ence for the internal echo signal evaluation. (Cf. teach reference)
Reference object Specified part, which is used for comparative measurements of the switch points and

Glossary
the detection fields. Synonymous with measurement object. (Cf. Object, Secondary
object)
Reflex barrier Extended function of an ultrasonic proximity switch. The USi safety monitors the area
between switch point smin and a taught-in reflector. Each change results in signal
change at the output. (Cf. Sonic barrier)
Reflex switch Basic function of an ultrasonic proximity switch. Objects in the detection field will be
detected, meaning sensed using the sonic lobe.
Renewed readiness time Time between the incident “Protection field empty again” and the release of the safe
outputs OSSD.
Repeatability Make a change to the real switching point under predetermined conditions. [IEC
60947‑5‑2, 2.3.4] Indicates the accuracy of measurement results, which have passed
through the same switch point with predetermined conditions. Synonymous with re-
producibility.
RESET Function in the parameterisation software that forces USi safety to restart. USi safety
starts with the settings released last.
Resolution Smallest unit of length, which can be differentiated by a proximity switch. Resolution
of the USi safety: 1 cm.
Restart delay Parameter value in the Standard tab of the parameterisation software that keeps the
outputs in the OFF state for a specific time after it has been detected that the detec-
tion field is empty again. The time value is predefined is the number of measurement
cycles.
Save parameters Function in the File menu of the parameterisation software that saves all parameters
from the GUI to a file of the type “.usi”. (Cf. Read parameters)
Secondary object Object in the detection field, which is not an object to be detected. Examples: ma-
chine parts, shelves, columns, etc. In order to prevent malfunctions, the USi safety will
be subjected to a Teach In of the environment incl. all secondary objects.(cf. Object)
Sensitivity Parameter value in the Expert mode tab of the parameterisation software that influ-
ences the evaluation of the incoming echo signals: the higher the parameter value,
the more sensitive. Possible parameter values are 1 to 10. In the delivery condition,
the parameter value Sensitivity is preset to 5.
Sensor Part of the USi safety, which can transmit the ultrasonic waves via the active surface
and receive resulting echoes. Up to two sensors can be connected to each USi safety.
The connection designations on the evaluation unit: U1 = Sensor 1, U2 = Sensor 2.
(cf. Ultrasonic transducer, transducer)
Signal output Output that transmit not safety-related signals to the subsequent control system.
(Cf. Output, OUT)
Single echo Function in the Diagnosis tab of the parameterisation software. A click on the button

Glossary
Single echo induces the parameterisation software to show a single incoming echo
signals in an oscillogram as a snapshot. (Cf. Fixed echo)
smin Formula for the minimum switching distance.
Sonic lobe Three-dimensional coverage range of a ultrasonic proximity switch.
Sound frequency Frequency of the sound waves that are sent by the sensor and form the sound beam.
With USi safety, up to three sound frequencies are used that are all in the ultrasonic
range.
Sound Pressure Level The sound pressure level is a sound-field descriptor with a logarithmic dimension for
describing the intensity of a sound. The sound pressure level is often indicated as SPL.
SPL Abbreviation for Sound Pressure Level.
Spurious echoes (Cf. Transverse reflections)
Standard A tab of the parameterisation software in which the standard parameters for USi safe-
ty can be set. (Cf. Expert mode, Diagnosis)
Supply voltage Voltage, which is externally connected to a device, in order to enable its operation.
The supply voltage should correspond to the connecting voltage US indicated on the
type plate of the device.
Interference suppression Reciprocal interference suppression: Parameter in the Expert mode tab of the param-
eterisation software, which defines how to handle the reciprocal interference of mul-
tiple ultrasonic sensors. The reciprocal interference parameter can be “off”, “medium”
or “high”. If reciprocal interference suppression is activated with the setting “medium”
or “high”, this will lengthen the Measurement cycle.
Switching distance Distance, at which a signal change at the output is caused by the approximation of a
measurement object to the active surface along the reference axis.
[IEC 60947‑5‑2, 2.3.1]
Switching frequency Number of switching operations of a proximity switch in a specified time interval.
[IEC 60947‑5‑2, 2.4.3]
Switching point Predefined switching distance. With USi safety, two switching points are always pre-
defined: Switching point SP1 for the protection field and switching point SP2 for the
warning field.
Switching point SP1 The sensor-close switching point of USi safety for the protection field. Applicable here:
SP1 < SP2. In the delivery condition, switching point SP1 is preset to 200 [cm].
Switching point SP2 The sensor-distant switching point of USi safety for the warning field. Applicable
here: SP2 > SP1. If SP2 = SP1, then there is no warning field. In the delivery condition,
switching point SP2 is preset to 200 [cm].

Glossary
Switch Proximity switch, which operates in the basic function measurement. The objective
of the evaluation of the echo signals is only to determine the two conditions “object
present” and “object not present”. (Cf. Detection)
Tab Graphical functional unit of the parameterisation software with index card design
that includes the all group fields belonging to the subject of the tab. The GUI has 7
tabs: Log in/out, Standard, Expert mode, Diagnosis, Multi sensors, Release and proto-
col.
Teach difference An option in the group field Oscillogram selection in the Diagnosis tab of the param-
eterisation software with which the illustration of the oscillogram is defined: Next to
the analogue echo signal, the difference to the saved reference image is displayed as
a curve.
Teach In Function in the Diagnosis tab of the parameterisation software that induces USi safety
to teach in the currently prevailing environment in the detection field and accept all
secondary objects as given. Automatically precedes every release test (Release tab).
Teach reference An option in the group field Oscillogram selection in the Diagnosis tab of the param-
eterisation software with which the illustration of the oscillogram is defined: Next to
the analogue echo signal, the saved reference image is displayed as a curve.
Temperature compensation Internal function of ultrasonic proximity switches, which balance the typical ultrasonic
temperature drift. (Cf. Temperature drift)
Temperature drift Deviating measurement behaviour of ultrasonic proximity switches dependent on

temperature. The typical ultrasonic temperature drift is generally balanced by internal
temperature compensation. (Cf. Temperature compensation)
Time Variable Gain A parameter in the Expert mode tab of the parameterisation software that defines
the run-time-dependent gain. Time Variable Gain (TVG) balances the damping factor
typical in the medium air, is always active and has a predefined characteristic line
that can be displayed in the oscillogram of the Diagnosis tab. TVG can be “TVG1”
or “TVG2”. In the delivery condition, the parameter Time Variable Gain is preset to
“TVG1”.
Transducer Abbreviated name for ultrasonic transducer. Referred to as sensor for USi safety.
(Cf. Sensor, Ultrasonic transducer)
Transmission burst Start sequence of an ultrasound bundle which is transmitted. May be heard as a
crackle.
Transverse reflections Unwanted echoes generated by unfavourable environmental conditions. Transverse

reflection can lead to malfunction of the ultrasonic proximity switch.
TVG Abbreviation for Time Variable Gain.
Ultrasonic frequency Sound frequency, with which an ultrasonic proximity switch operates.
Ultrasonic proximity switch Proximity switch, which transmits ultrasonic waves in an active zone and receives a

Glossary
semiconductor switching element. [IEC 60947‑5‑2, 2.1.1.3] (Cf. Proximity switch)
Ultrasonic transducer Part of an ultrasonic proximity switch, which can transmit the ultrasonic waves via the
active surface and receive resulting echoes. Referred to as sensor for USi safety. (Cf.
Sensor, Transducer)
USi Abbreviation for ultrasonic industrial sensor.
USi safety Short name for USi as a contactless protective device (optoelectronic protective de-
vice).
Warning field The detection field area upstream of the protective field. A change in the warning
field affects only the signal outputs OUT. (Cf. Protection field)
Write parameters Function in the tabs Standard and Expert mode of the parameterisation software that
transfers all – changed and not changed – parameters from the GUI to USi safety.
(Cf. Read parameters)

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What is the intended use of the USi safety sensor?

What is the intended use of the USi safety sensor?

What are the main components of the USi safety sensor?

What are the main components of the USi safety sensor?

Innovative by tradition.

Ultrasonic industrial sensor USi® safety

1006504 USi® safety *

* in addition sensor 1005264

Mayser GmbH & Co. KG

Page 2/107 Operating instructions USi safety 211019 v2.00

Mounting the temperature sensor................................................................................................................................ 31

211019 v2.00 Operating Instructions USi safety Page 3/107

Checking the detection field..............................................................................................................................................79

Page 4/107 Operating instructions USi safety 211019 v2.00

About this manual

This manual is an integral part of the product.

ÄÄ Read the manual carefully before use.

ÄÄ Pass the manual on to every subsequent owner or user of the product.

ÄÄ Add any supplement received from the manufacturer to the manual.

Symbols used Symbol Meaning

1. ... Action with several steps whose order is relevant.

• ... Bullets first level

(see Section Installation) Cross-reference

211019 v2.00 Operating Instructions USi safety Page 5/107

Danger symbols and Symbol Meaning

WARNING Imminent danger which may lead to death or serious injury

CAUTION Possible danger which may lead to minor or moderate

Information on easier and safer working practices

Page 6/107 Operating instructions USi safety 211019 v2.00

The product complies with ISO 13849-1:2015 Category 3 PL d. So that the

211019 v2.00 Operating Instructions USi safety Page 7/107

ÄÄ Do not open sensors (ultrasonic transducer)

ÄÄ Do not squeeze the sensors

ÄÄ Check supply voltage

ÄÄ Observe degree of protection

ÄÄ Protect from sunlight

ÄÄ Do not alter special cable

ÄÄ Observe PIN assignment

ÄÄ Do not overload evaluation unit

ÄÄ Replacing wear parts

ÄÄ In the event of a fault, take out of operation

Page 8/107 Operating instructions USi safety 211019 v2.00

Tip: You can find recommended accessories in chapter Accessories.

Transport and storage

Packaging and transport

The USB stick (parameterisation software) is enclosed loosely.

ÄÄ Observe the storage temperatures given in the technical specifications.

211019 v2.00 Operating Instructions USi safety Page 9/107

Sensor (ultrasonic transducer)

1 Sensor (ultrasonic transducer) 3 M8 plug

5 Fastening point (M4) 8 M8 socket X2: RS485, TEMP

Page 10/107 Operating instructions USi safety 211019 v2.00

•• Green LED “OSSD“:

•• Yellow LED “OUT“:

View with covers.

View without covers: 8 M8 socket X2: RS485, TEMP

211019 v2.00 Operating Instructions USi safety Page 11/107

Connection Type Explanation

Plug X1 Signal PIN Circular connector