Ultrasonic Sensors for Harsh Environments

Senix’s compact, rugged, ultrasonic sensors inspired the name “ToughSonic.” These sensors are Senix’s flagship products comprising heavy-duty electronics epoxy potted into type 316 stainless steel housings. They also contain ruggedized piezoelectric transducers and permanently attached cables.

ToughSonic® sensors are used in remote monitoring locations from the Alaskan oil fields to the Australian outback. The sensors can be set up in the most severe factory settings and on heavy construction and farm equipment. Users can rely on ToughSonic® when a standard sensor fails to meet their requirements.

Product Line Features

  • The sensors can be used both indoors and outdoors
  • Operating temperature: –40 °C to 70 °C
  • Detect objects, compute distance, and measure and regulate benign liquid and water levels
  • Ingress: IP68, NEMA-6P, and NEMA-4X
  • User-modifiable with SenixVIEW software (included) for testing, installation, and cloning sensors

ToughSonic® 3

  • Maximum/optimum range—3 ft (0.9 m)/2 ft (0.6 m)
  • Deadband—0–1.75″ (0–44 mm)
  • Transducer—Standard, beam width 12 +/– 2°
  • Mounting threads
    • US: 1-inch NPT
    • Metric: 30 x 1.5 mm
  • Dimensions—Length: 4.062″ (103.2 mm); diameter: 1.32″ (33.3 mm) maximum
  • Selectable outputs—2 plus serial data; voltage, current, and switch(es)
  • Adjustment—SenixVIEW and push-button “teachable”
  • Cable—6.5 ft (2 m) pigtail, 4- or 6-wire + drain
  • Serial data-only models—Cable: 4-wire + drain (dual-twisted pair)

ToughSonic® 12

  • Maximum/optimum range12 ft (3.7 m)/8 ft (2.4 m)
  • Deadband0–3″ (0–76 mm)
  • TransducerKynar (PVDF), beam width 10 +/– 2°
  • Mounting threads
    • US: 1-inch NPT
    • Metric: 30 x 1.5 mm
  • Dimensions—Length: 4.062″ (103.2 mm); diameter 1.32″ (33.3 mm) maximum
  • Selectable outputs—2 plus serial data; voltage, current, and switch(es)
  • Adjustment—SenixVIEW and push-button “teachable”
  • Cable—6.5 ft (2 m) pigtail, 4- or 6-wire + drain
  • Serial data-only models—Cable: 4-wire + drain (dual-twisted pair)

ToughSonic® 14

  • Maximum/optimum range—14 ft (4.3 m)/10 ft (3 m)
  • Deadband—0–4″ (0–102 mm)
  • Transducer—Standard, beam width 12 +/– 2°
  • Mounting threads
    • US: 1-inch NPT
    • Metric: 30 x 1.5 mm
  • Dimensions—Length: 4.062 in (103.2 mm); diameter: 1.32 in (33.3 mm) maximum
  • Selectable outputs—2 plus serial data; voltage, current, and switch(es)
  • Adjustment—SenixVIEW and push-button “teachable”
  • Cable—6.5 ft (2 m) pigtail, 4- or 6-wire + drain
  • Serial data-only models—Cable: 4-wire + drain (dual-twisted pair)

ToughSonic® 30

  • Maximum/optimum range—30 ft (9.1 m)/20 ft (6.1 m)
  • Deadband—0–10″ (0–254 mm)
  • Transducer—Standard, beam width 15 +/– 2°
  • Mounting threads—US: 1-1/2″ NPT, both ends threaded
  • Dimensions—Length: 4.30″ (109 mm); diameter: 1.88″ (48 mm)
  • Simultaneous outputs—5 plus serial data; 1 voltage, 2 current, and 2 switches
  • Adjustment—SenixVIEW and push-button “teachable”
  • Cable—6.5 ft (2 m) pigtail, 4- or 9-wire + drain
  • Serial data-only models—Cable: 4-wire + drain (dual-twisted pair)

ToughSonic® 50

  • Maximum/optimum range—50 ft (15.2 m)/33 ft (10 m)
  • Deadband—0–12″ (0–303 mm)
  • Transducer—Standard, beam width 12 +/– 2°
  • Mounting options—Clamp, or 1-1/2″ NPT rear, or PVC 2-1/2″ NPT front and rear
  • Dimensions (D x L)—Dimensions can be obtained model-wise
  • Simultaneous Outputs—5 plus serial data; 1 voltage, 2 current, and 2 switches
  • Adjustment—SenixVIEW adjustable only, no push-button
  • Cable—6.5 ft (2 m) pigtail, 4- or 9-wire + drain
  • Serial data-only models—Cable: 4-wire + drain (dual-twisted pair)

Smart Communications

Each sensor is equipped with serial data communications to connect with the user’s equipment or SenixVIEW setup software. The RS-232 or RS-485 model can be selected as per the communications format given below:

  • Selectable Modbus (default) or ASCII streaming protocols
  • Baud rates from 9600 (default) to 115200 bps
  • Several other features, all modifiable using SenixVIEW software

The RS-485 Serial Data Interface is suggested unless linking up to an RS-232 device. The advantages of RS-485 over RS-232 are given below:

  • Permits longer cable lengths at higher baud rates
  • Improved noise immunity in industrial settings
  • Multi-sensor Modbus-addressable RS-485 networks
  • Bottom line: Extra capability and high value

The sensors power-on and readily measure within a second, thus energy is saved in battery-driven applications. When only a serial data interface is desirable, all models are available without the extra analog and switch outputs at a cost-effective rate with less usage of power, and they also use a 4-wire dual twisted pair (plus drain) data cable instead of the basic 6- or 9-wire cable.

Smart Interfaces

Multiple Outputs

  • SenixVIEW adaptable
  • ToughSonic® 3, 12, 14: Two concurrent outputs + serial data
  • ToughSonic® 30, 50: Five concurrent outputs + serial data
  • Analog 0–10 VDC and 4–20 mA
  • Serial data communications (RS-232 or RS-485)
  • Push-button adjustments in all models except ToughSonic® 50
  • Switches: Configurable as Sourcing (PNP) or Sinking (NPN)

Maximum Flexibility

Sensor outputs are SenixVIEW configurable

  • Analogs can be adjusted between any two distances, negative or positive slope, modifiable analog limits, and no-target time delay
  • Switches come in both hysteresis and window modes, time delays (on, off, and no target)
  • All switches and analogs comprise response settings for power-on initialization, SYNC lost, and loss of target echo (delay and state)

Smart Teach Button

Sensors are available with a default configuration; however, several features can be modified using the rear push-button (except with ToughSonic® 50). It is also possible to reset the default configuration by using the push-button, or by deactivating the button.

Adjustment is stronger and easier when the SenixVIEW software is used.

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