LAB MANUAL

ELECTRICAL AND ELECTRONICS

MEASUREMENT USING
ADVANCED SENSORS

BAJAJ ENGINEERING SKILLS

TRAINING (BEST) CENTRE

BANASTHALI VIDYAPITH
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 List of Experiments
S. No. Experiment Page No.
1 Operation of analog vibration sensor using turck software and IO-Link 1
2 Operation of analog Q4X stainless steel LASER Sensor using IO-Link. 4
3 Operation of analog distance sensor using IO-Link. 9
4 Operation of analog diffuse mode sensor using IO-Link. 13
5 Operation of analog 2D Lidar Sensors. 16
6 Study of magnetic-coded sensors using IO-Link. 19

List of Figures
S. No. Name of Figure Page No.
1 Figure 1.1: Vibration sensor 1
2 Figure 1.2: IO-Link Master 2
3 Figure 2.1: Q4X Stainless Steel Laser Sensor 4
4 Figure 2.2: Display in Run Mode 5
5 Figure 3.1: Distance sensor 9
6 Figure 3.2: Distance sensor top view 9
7 Figure 3.3: Distance sensor Mode rotary switch 10
8 Figure 4.1: Diffuse mode sensor 12
9 Figure 4.2: Diffuse mode sensor top vi 13
10 Figure 5.1: 2D Lidar Sensor 15
11 Figure 5.2: 2D Lidar Sensors connection pc and power su 16
12 Figure 5.3: Scanning range (in meter) 17
13 Figure 6.1: Magnetic-coded Sensors 18
14 Figure 6.2:Connection diagram 19

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 Experiment No. 1
Objective
Operation of analog vibration sensor using turck software and IO-Link.

Apparatus Required
S. No. Product Name Product No. Quantity

1 Vibration Sensor MP0310 1

2 Electrical Connection Set MP0027 1

3 PLC Kit assy MP0157 1

4 Switching Mode Power Supply JTK-SMPS 1

5. IO-Link MP0315 1

Theory
1. Vibration Sensor- The vibration sensor detects the vibration in the system (measured /
evaluated physical unit = vibration velocity). This is converted into an analogue signal at the
current output. The switching output behavior is determined using the two setting rings.

Figure 1.1: Vibration sensor

i. Locking ring
ii. Setting rings (manually adjustable after unlocking)
iii. LED green: voltage supply
iv. M8 process connection

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 v. LED yellow: lights when switching threshold and time delay are exceeded
vi. Setting marks
Setting Marks-
RMS Set- Effective value of the switching threshold, defining the limit value of the vibration
velocity.
Delay Set- Time in seconds during which the limit value must be effectively above the switching
threshold (RMS Set) to activate the switching output (normally closed pin 4).
2. IO-Link-
IO-Link enables seamless communication and digital data transfer from the control level right
down to the sensor level. Intelligent devices can be used to their full potential with IO-Link,
paving the way for Industry 4.0 in automation technology. The internationally standardized
interface provides value at all stages, from plant design to installation right through to operation
and maintenance, by sustainably reducing costs and increasing efficiency.

Figure 1.2: IO-Link Master

Standardized device description files (IODDs) and parameterization via software tools ensure
convenient configuration and integration of IO-Link sensors and actuators. Intelligent and
transparent parameter management increases flexibility within the application and minimizes
downtime. Parameters can be adjusted quickly and easily, even during complex production
changes and batch changes. With transparency right through to the sensor, users have access to a

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comprehensive range of parameterization options and device diagnostic functions, allowing them
to carry out predictive maintenance.

Procedure-
Turck software configuration with sensor-
1. Open turck Service tool.
2. On that click Search. It will show all connected devices.
3. IP address should be in same network with host computer.
4. After assigning IP address. Type the IP on browser that will open station information
page on browser.
5. Type ―password‖ in LOGIN box Then Click analog input 0.
6. Click on Parameters window select ―current‖ in operation mode. Select ―4…20mA‖ in
current range.
7. Select ―single ended‖ in current wiring type and select ―50 Hz‖ in Mains Suppression.
8. Then Click Submit. Do the same procedure for all other analog inputs (if you are
connecting sensors with that inputs) analog input 1, analog input 2 and analog input3.
9. If you are not connecting sensors with analog input – deactivate that channel.
Result- We have successfully done the operation of analog vibration sensor using turck software
and IO-Link.

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 Experiment No. 2
Objective
Operation of analog Q4X stainless steel LASER sensor using IO-Link.

Apparatus Required
S. No. Product Name Product No. Quantity

1 Q4X Stainless Steel Laser Sensor MP0306 1

2 Electrical Connection Set MP0027 1

3 Switching Mode Power Supply JTK-SMPS 1

4 IO-Link MP0315 1

Theory
The Q4X Series by Banner is highly versatile and precise, and offers a reliable sensing range of
25 to 300 mm. The laser technology measures on a wide variety of target colors, materials, and
surfaces. This versatile, rugged laser distance sensor offers superior performance and can detect
sub-millimeter changes in distance. Discrete, analog (0-10 V or 4-20 mA), and clear object
models are available.

Figure 2.1: Q4X Stainless Steel Laser Sensor

1. Output Indicator (Amber)

2. Display
3. Buttons

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 Figure 2.2: Display in Run Mode

The display is a 4-digit, 7-segment LED. The main screen is the Run Mode screen, which shows
the current distance to the target in millimeters.
1. Stability Indicator (STB = Green)
2. Active TEACH Indicators
i. DYN = Dynamic (Amber)
ii. FGS = Foreground Suppression (Amber)
iii. BGS = Background Suppression (Amber)
3. Output Indicator
i. On—Outputs conducting (closed)
ii. Off—Outputs not conducting (open)
4. Stability Indicator (STB)
i. On- Stable signal within the specified sensing range.
ii. Flashing- Marginal signal, the target is outside the limits of the specified sensing
range, or a multiple peak condition exists.
iii. Off—No target detected within the specified sensing range.
Active TEACH Indicators (DYN, FGS, and BGS)
1. DYN, FGS, and BGS all off = Two-point TEACH mode selected (default)
2. DYN on = Dynamic TEACH mode selected
3. FGS on = Foreground suppression TEACH mode selected
4. BGS on = Background suppression TEACH mode selected
Buttons
1. (SELECT)(TEACH)
i. Press to select menu items in Setup mode
ii. Press and hold for longer than 2 seconds to start the currently selected TEACH
mode (the default is two-point TEACH)

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 2. (+)(LO/DO)
i. Press to navigate the sensor menu in Setup mode
ii. Press to change setting values; press and hold to increase numeric values
iii. Press and hold for longer than 2 seconds to switch between light operate (LO) and
dark operate (DO)
3. (-)(MODE)
i. Press to navigate the sensor menu in Setup mode
ii. Press to change setting values; press and hold to decrease numeric values
iii. Press and hold for longer than 2 seconds to enter Setup mode
SETUP MODE
Access Setup mode and the sensor menu from Run mode by pressing and holding MODE for
longer than 2 seconds. Use + and - to navigate through the menu. Press SELECT to select a
menu option and access the submenus. Use + and - to navigate through the submenus. Press
SELECT to select a submenu option and return to the top menu, or press and hold SELECT for
longer than 2 seconds to select a submenu option and return immediately to run mode.
To exit Setup mode and return to run mode, navigate to End and press SELECT.

Procedure
The analog output type can be configured as voltage or current output via IO-Link.
Turck software configuration with sensor-
1. Open turck Service tool.
2. On that click Search. It will show all connected devices.
3. IP address should be in same network with host computer.
4. After assigning IP address. Type the IP on browser that will open station information
page on browser.
5. Type ―password‖ in LOGIN box Then Click analog input 0.
6. Click on Parameters window select ―current‖ in operation mode. Select ―4…20mA‖ in
current range.
7. Select ―single ended‖ in current wiring type and select ―50 Hz‖ in Mains Suppression.

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 8. Then Click Submit. Do the same procedure for all other analog inputs (if you are
connecting sensors with that inputs) analog input 1, analog input 2 and analog input3.
9. If you are not connecting sensors with analog input – deactivate that channel.
TEACH modes include
1. Two-point static background suppression z-pt - Two-point TEACH sets a single switch
point. The sensor sets the switch point between two taught target distances, relative to
the shifted origin location.
2. Dynamic background suppression dyn- Dynamic TEACH sets a single switch point
during machine run conditions. The sensor takes multiple samples and the switch point
is set between the minimum and the maximum sampled distances.
3. One-point window (foreground suppression) FG5- One-point window sets a window
(two switch points) centered on the taught target distance.
4. One-point background suppression bc5- One-point background suppression sets a single
switch point in front of the taught target distance. Objects beyond the taught switch point
are ignored.
Manual Adjustments
Manually adjust the sensor switch point using the + and - buttons.
1. From Run mode, press either + or - one time. The current switch point value flashes
slowly.
2. Press + to move the switch point up or - to move the switch point down. After 1 second
of inactivity, the new switch point value flashes rapidly, the new setting is accepted, and
the sensor returns to run mode.
3. When FGS mode is selected (the FGS indicator is on), manual adjustment moves both
sides of the symmetrical threshold window simultaneously, expanding and collapsing the
window size. Manual adjustment does not move the center point of the window.
Light Operate/Dark Operate
The default output configuration is light operate. To switch between light operate and dark
operate, use the following instructions:
1. Press and hold LO/DO for longer than 2 seconds. The current selection displays.
2. Press LO/DO again. The new selection flashes slowly.

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 3. Press SELECT to change the output configuration and return to run mode.

Result
We have successfully done the operation of analog Q4X stainless steel LASER sensor using IO-
Link.

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 Experiment No. 3
Objective
Operation of analog distance sensor using IO-Link.

Apparatus Required
S. No. Product Name Product No. Quantity

1 Distance Sensor MP0307 1

2 Electrical Connection Set MP0027 1

3 Switching Mode Power Supply JTK-SMPS 1

4 IO-Link MP0315 1

Theory
The optical sensors in the series are the first devices to offer an end-to-end solution in a medium-
sized standard design – from the thru-beam sensor through to the measuring distance sensor. As
a result of this design, the sensors are able to perform practically all standard automation tasks.
The entire series enables sensors to communicate via IO-Link.

Figure 3.1: Distance sensor

Figure 3.2: Distance sensor top view

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 1. Mode rotary switch
2. Teach-in button
3. Switching output display Q1- YE
4. Operating indicator - GN

Figure 3.3: Distance sensor Mode rotary switch

1. Q1B - Switching output/switch point B

2. Q1A - Switching output/switch point A
3. Q2A - Analog output/value A
4. Q2Ã - Analog output/value B
5. 0 - Keylock
The following operating modes are available:
i. Absolute mode (default setting)
ii. Normalized mode
iii. Rising slope
iv. Falling slope
Procedure
The analog output type can be configured as voltage or current output via IO-Link.
Turck software configuration with sensor-
1. Open turck Service tool.
2. On that click Search. It will show all connected devices.
3. IP address should be in same network with host computer.
4. After assigning IP address. Type the IP on browser that will open station information
page on browser.
5. Type ―password‖ in LOGIN box Then Click analog input 0.

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 6. Click on Parameters window select ―current‖ in operation mode. Select ―4…20mA‖ in
current range.
7. Select ―single ended‖ in current wiring type and select ―50 Hz‖ in Mains Suppression.
8. Then Click Submit. Do the same procedure for all other analog inputs (if you are
connecting sensors with that inputs) analog input 1, analog input 2 and analog input3.
9. If you are not connecting sensors with analog input – deactivate that channel.
Teach-In (TI)
Use the rotary switch for switching signal Q1 to select the relevant switching threshold A and B
to teach in.
1. The yellow LEDs indicate the current state of the selected output.
2. To teach in a switching threshold, press and hold the "TI" button for approximately 1 s,
until the yellow and green LEDs flash in phase. Teach-in starts when the "TI" button is
released.
3. Teach-in successful: the yellow and green LEDs flash alternately at 2.5 Hz.
4. Teach-in unsuccessful: the yellow and green LEDs quickly flash alternately at 8 Hz.
5. After an unsuccessful Teach-in, the sensor continues to operate with the previous valid
setting after the relevant visual fault signal is issued.
6. Set switching mode: you can define different switching modes by teaching in the relevant
distance data for switching thresholds A and B.
7. Teach in switching thresholds: you can teach in or overwrite a taught-in switching
threshold at any time. To do this, press the "TI" button again.
8. Reset a value: you can reset a taught-in value. To do this, press the "TI" button for > 4 s,
until the yellow and green LEDs go out.
9. The reset process itself starts when the "TI" button is released.
10. Reset successful: the yellow and green LEDs flash alternately at 2.5 Hz.
11. Minimum and maximum values for the analog output Q2 are taught in and deleted in the
same way as those for the switching output.
Result
We have successfully done the operation of analog distance sensor using IO-Link.

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 Experiment No. 4
Objective
Operation of analog diffuse mode sensor using IO-Link.

Apparatus Required
S. No. Product Name Product No. Quantity

1 Diffuse mode Sensor MP0305 1

2 Electrical Connection Set MP0027 1

3 Switching Mode Power Supply JTK-SMPS 1

4 IO-Link MP0315 1

Theory
The optical sensors of this series are suitable for both standard and demanding applications. The
series features a miniature housing design, two M3 metal-threaded mounting holes and a highly
visible LED status indicator. Each device is equipped with a sensitivity adjuster and a light-
on/dark-on changeover switch for increased flexibility. A wide variety of versions are available
in both infrared light and red light with Power Beam for easy alignment. Special versions with
Blue Beam are suitable for challenging applications like those in the solar and battery industries.
Diffuse mode sensor, plastic housing, 1000 mm adjustable detection range, red light, light/dark
on, PNP output, M8 plug 4-pin
The entire series enables sensors to communicate via IO-Link.

Figure 4.1: Diffuse mode sensor

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 Figure 4.2: Diffuse mode sensor top view

1. Light-Dark-switching
2. Sensitivity adjuster
3. Signal display yellow
4. Operating display green

Procedure
The analog output type can be configured as voltage or current output via IO-Link.
Turck software configuration with sensor-
1. Open turck Service tool.
2. On that click Search. It will show all connected devices.
3. IP address should be in same network with host computer.
4. After assigning IP address. Type the IP on browser that will open station information
page on browser.
5. Type ―password‖ in LOGIN box Then Click analog input 0.
6. Click on Parameters window select ―current‖ in operation mode. Select ―4…20mA‖ in
current range.
7. Select ―single ended‖ in current wiring type and select ―50 Hz‖ in Mains Suppression.
8. Then Click Submit. Do the same procedure for all other analog inputs (if you are
connecting sensors with that inputs) analog input 1, analog input 2 and analog input3.
9. If you are not connecting sensors with analog input – deactivate that channel.
Teach-In (TI)

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Use the rotary switch for switching signal Q1 to select the relevant switching threshold A and B
to teach in.
1. Light-Dark-switching- set the switch at dark or light mode.
2. Sensitivity Adjust by rotary switch (2) - when adjust rotary switch then operating range
increased or decreased automatically.
3. Operating display green- when apply power supply to sensor then green LED will be
glow.
4. Signal display yellow- when object in front of light then yellow LED will be glow.
Result
We have successfully done the operation of analog diffuse mode sensor using IO-Link.

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 Experiment No.5
Objective
Operation of analog 2D Lidar Sensors.

Apparatus Required
S. No. Product Name Product No. Quantity

1 2D Lidar Sensors MP03012 1

2 Electrical Connection Set MP0027 1

3 Switching Mode Power Supply JTK-SMPS 1

4 IO-Link MP0315 1

5 SOPAS Engineering Tool software - 1

Theory
2D Lidar sensor is intended for use as a non-contact measurement sensor in standalone
operation. It measures radial distances within a flat surface (circle segment) depending on
reflectivity. The sensor displays the measured values of the recorded environment contour of its
scanning angle of 270° over the Ethernet or USB interface for further processing as either a on-
off or continuously on request. This requires a corresponding driver to be created by the user.
The device is designed for portable or stationary use indoors or outdoors in standalone operation,
with a scanning range of up to 10 m.

Figure 5.1: 2D Lidar Sensor

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 1. Connect the communication interface of the TiM to the PC (Ethernet or USB;
recommended Ethernet, 4-pin M12 outlet). PC in the SOPAS communication software,
select Communication Go Online.
2. Turn on and start the PC. Provide power to the TiM (5-pin M12 plug). Using the power
supply unit it must be ensured that the supply voltage does not drop below 8 V for longer
than 2ms and never rises above 30 V.
3. Successful initialization, the green LED lights up " ▸" (device ready for operation).

Figure 5.2: 2D Lidar Sensors connection PC and power supply

Procedure
1. Open the SOPAS Engineering Tool.
2. Establish communication between SOPAS and TiM via the wizard that has started
automatically: Select connect to a new device.
3. Follow the steps in the Connection Wizard until the Found devices window.
4. Select the appropriate TiM from the list of available devices:
i. Use TiM on port 561 to configure the device.
ii. Default IP address of the TiM:

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 5. Assign the required IP address/subnet mask to the TiM via automatically or manually.
The IP address/subnet mask should correspond to the address space of the later
application.
6. Click finish to quit the Connection Wizard. SOPAS ET establishes communication with
the TiM, loads its current device description (parameters), and displays it in the
navigation tree.

Output range of the measured values

The TiM scans an angle range of 270°(-45° to 225°) and outputs 271 measured values per scan in
the default setting. The angle range, for measured values, output can be set via Output range
(TiM55x: resolution 1°, TiM56x: resolution 0.33°).

Figure 5.3: Scanning range (in meter)

Result
We have successfully done the operation of analog 2D Lidar Sensors.

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 Experiment No. 6
Objective
Study of magnetic-coded sensors using IO-Link.

Apparatus Required
S. No. Product Name Product No. Quantity

1 Magnetic-coded Sensors MP03011 1

2 Electrical Connection Set MP0027 1

3 Switching Mode Power Supply JTK-SMPS 1

4 IO-Link MP0315 1

Theory
The magnetically-coded sensor (with safety relay) is designed for use in protective door
monitoring according to EN ISO 14119. These devices are designed for safety-related
monitoring of movable safety guards. The sensor and the actuator may only be used if they are
mounted, connected, put into operation and tested according to the applicable operating
instructions, the relevant rules, standards and regulations concerning occupational health and
safety and by a qualified person (qualified electrician trained in safety matters).

Figure 6.1: Magnetic-coded Sensors

The unit consists of a sensor and an actuator. The sensor features reed contacts that are activated
without contact thought the coded magnetic field of the actuator. If a hatch or a door is opened,
the magnetically coded actuator moves away from the sensor which is positioned on the
stationary part of the guard.

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 Figure 6.2:Connection diagram

Procedure
Operate the sensors with the corresponding permissible actuators and safety relays. Only using
components that are adapted to each other guarantees correct safety-related functioning.
The analog output type can be configured as voltage or current output via IO-Link
1. Protect the sensor and the actuator from foreign bodies.
2. When the device is mounted directly to ferromagnetic materials, using a spacer is
mandatory.
3. Take measures to avoid ferromagnetic objects being placed intentionally or
unintentionally on the sensing face.
4. Adhere to EN ISO 14119 for interlocking devices associated with guards.
5. The protective equipment must be dimensioned and mounted in a way to prevent persons
can walk or touch behind it.
6. The sensor and the actuator may neither be manipulated nor may their correct position be
changed.
7. The additional signal contact is for status indication. It is not permitted to use it as a
safety-related contact.
8. Do not use any different magnets and do not bridge any contacts.
9. Do not use the device as an end stop.
10. Only use cable glands, insulation material and connecting wires that have an appropriate
protection rating.
11. Adhere to the principle of normally closed operation for all external safety circuits
connected to the system.
12. Sensors and actuators must be protected from strong shocks and vibrations. Observe the
permissible environmental conditions.
Result
We have successfully study the magnetic-coded sensors using IO-Link.
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