Helping you #Make Sense of Sensors
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FILLING & LEVEL MONITORING APPLICATIONS Contrinex sensors are trusted on filling machines - Boxes, bottles and beyond.
FILLING APPLICATIONS
During secondary packaging of bags of confectionery, manufacturers arrange bags in overlapping layers. Multi-axis pick-and-place packing robots align and pack layers of bags in preformed cardboard cartons. The filled cartons are conveyed to case-sealing stations. A highly reliable photoelectric sensor, mounted directly above the conveyor, senses the height of the top layer of bags in each carton before sealing and rejects insufficiently filled cartons. CUSTOMER APPLICATION In the food processing industry, shingling, or overlapped layering, is a common technique for optimising space utilisation during secondary packaging operations. Confectionery, sealed in gusseted bags with predominantly triangular profiles, is packed in alternating, overlapping layers in preformed cardboard cartons. Once each carton is full, it passes to a case-sealing station prior to palletization and dispatch. Pre-aligned bags of confectionery arrive at the packing station in regularly spaced rows. At each station, a multi-axis pick-and-place packing robot lifts a row of bags, aligns it and lowers it into a preformed carton. Successive layers overlap each other, ensuring that space within the carton is fully utilised. Once the predetermined number of layers has been packed, the carton is conveyed to the sealing station. From time to time, one or more incorrectly formed layers occur. Individual bags may be missing from a row on arrival at the packing station, or may be damaged or misaligned. A non-contact sensor is needed to sense the height of the top layer of bags, rejecting any defective cartons. It must be reliable and require minimal maintenance.
Customer Solution Rugged photoelectric sensors with background suppression from the Contrinex C23 range are ideal for this application. A pinpoint red LED with a 10mm-diameter light spot at the maximum sensing range of 300mm ensures highly reliable detection of objects of almost any colour against light or dark backgrounds. These sensors are well suited to both the task and the environment. Immediately after packing, a single sensor is mounted centrally above the conveyor. As each carton passes below on its way to the sealing station, the sensor detects the top surface of the packed bags. If the height of the top layer falls outside preset limits, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC-sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Locating sensors optimally is simple thanks to a custom-designed range of multi-position mounting brackets. An operating range between 15mm and 250mm accommodates a variety of carton sizes without any need to reposition the sensor. A simple electrical adjustment via an onboard potentiometer suffices, while remote adjustment via IO-Link, a standardized point-to-point serial connection protocol, is available as standard at no extra cost for PNP versions.
APPLICATION - CONFECTIONERY BOX OVERFILL CHECK
APPLICATION - POST-FILLING CHECK OF ALUMINIUM CLOSURES
A food-processing plant trusts Contrinex’s sensors to help it ensure plastic bottles, filled with liquid food products, are hermetically sealed and its customers kept safe. Prior to the containers being capped, a long-distance inductive sensor, positioned directly over the packaging line confirms the presence of an aluminium-foil seal over the top of every container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilised as seals for plastic containers filled with ketchup, mustard and other table sauces. At a food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging. From time to time, equipment malfunctions can occur and containers leave the sealing station without closures in place. If unsealed containers are not detected prior to capping, entire batches of product may require manual inspection, resulting in lost production, down-time or potential rejection by customers. An in-line sensor system inspecting each container could confirm the presence of a foil closure, rejecting any faulty items. Each production line processes containers in batches; successive batches may comprise filled containers of differing sizes. The system must accommodate containers whose heights vary by up to 20mm, without adjustment of sensors between batches as successive batches may comprise containers of differing sizes.
Customer Solution Contrinex Extra Distance inductive sensors are ideal for this application. M30-diameter units from the range operate reliably at sensing distances up to 40mm; a single sensor thus accommodates the entire range of container heights. Robust construction with chrome-plated brass bodies and PBTP sensing faces ensures that these devices are suitable for a busy production environment. A single sensor, located immediately after the sealing station and positioned directly above the production line, provides reliable, repeatable and fast detection of the aluminium-foil closures. With a switching frequency of up to 100Hz, this Extra Distance unit is well suited for fast-moving production where high-speed sensing is required. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 cable connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC- sheathed cable. With an unmatched combination of 40mm sensing distance in an M30- diameter device, the customer can now test the entire range of containers without adjusting the sensor height between batches. Contrinex Extra Distance inductive sensors deliver exceptionally reliable test results at production-line speed, without interruption.
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CUSTOMER VALUES • Reliable, repeatable in-line quality checks on a non-contact basis • Improved quality arising from real-time detection of incorrectly packed cartons • Increased productivity as stability alarm flags preventative-maintenance needs • Single sensor accommodates a range of carton sizes without repositioning • Remote adjustment via IO-Link reduces changeover time between products
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PRODUCT ADVANTAGES • Maximum sensing range of 300mm with pinpoint red LED • Best-in-class background-suppression black/white behaviour • IO-Link connectivity available at no extra cost on PNP versions • Dual output with stability alarm
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CUSTOMER VALUES • Reliable, repeatable in-line testing of a range of different-sized containers • Testing is completed without difficulty at production-line speed • Immediate identification of containers with missing closures • Elimination of manual inspection and potential batch rejection
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PRODUCT ADVANTAGES • Extended sensing distances up to 40mm • Unmatched combination of 40mm sensing distance in M30-diameter device
A Swiss meat-processing plant uses non-contact ultrasonic presence sensing to increase productivity and eliminate breakdowns when washing empty meat bins. A single ultrasonic sensor, mounted above the conveyor on which the bins travel, checks for meat residues, rejecting any contaminated bins before the wash station. Old, contact- based systems were unreliable, resulting in breakdowns and frequent interruptions to the washing process. CUSTOMER APPLICATION During production, an industrial meat-processing company conveys meat portions around its factory in food-grade plastic bins. After completion of each batch, empty bins are washed prior to reuse. Some bins contain sizeable pieces of meat which, if undetected, accumulate in the washing machine, causing blockages and breakdowns. The resulting interruptions to production are unacceptably frequent. A reliable sensor system must detect the presence of meat residues in bins as they travel along the conveyor. The sensor should identify all non-trivial residues and divert contaminated bins before they enter the washing station. The system should require little or no regular maintenance, and a non-contact sensor, suitable for a hygienic environment, is preferred. Old systems with spring-loaded wand-actuators in contact with the box are unreliable and require regular adjustment; the contact probes need frequent, time-consuming cleaning. The new system has to operate on a fit-and-forget basis.
Customer Solution Contrinex ultrasonic sensors are ideal for presence- and level-sensing applications, and a diffuse sensor from the Compact range (housing size M30) is an excellent choice for this application. Operating range for this metal-bodied, IP65-rated device is between 20cm and 130cm; detection is independent of the target’s color, shape, material or surface structure. Contrinex Compact ultrasonic sensors feature an integral S12 cable connector, allowing rapid disconnection and removal when required. The variable size and shape of meat residue makes it difficult for an uncompensated sensor to detect contamination consistently and reliably; potentiometer adjustment, provided by many manufacturers, is inadequate for this application. Contrinex CONPROG software for Windows®, connected via the APE-0000-001 PC interface, compensates perfectly. Using CONPROG, the operator characterizes the target area of the box during set-up, setting the exact operating parameters of the sensor and ensuring reliable detection. Sensor data is stored, allowing like-for-like sensor replacement without additional set-up. The sensor’s three-wire PNP normally-open output communicates directly with the customer PLC. On detection of a contaminated box, a mechanical diverter shunts the box to a separate conveyor for manual emptying.
APPLICATION - ULTRASONIC SENSORS CHECK OF MEAT BINS ON WASH LINE
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CUSTOMER VALUES • Improved sensor reliability derived from exact characterization of target • Increased productivity arising from elimination of breakdowns • Reduced sensor maintenance resulting from non-contact operation • Industry-standard interface requires little modification to control systems
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PRODUCT ADVANTAGES • Characterised sensors detect targets of variable size and shape • Long-distance, non-contact operating principles • IP65 protection allows operation in hygienic environments • Rugged ultrasonic sensor with metal housing and metal cable connector
During high-speed production of retail bags, a confectionery manufacturer conveys individual bags of sweets to a pick-and-place packing robot for secondary packaging. A highly reliable diffuse-mode photoelectric sensor, mounted beside the conveyor, detects the presence of bags as they approach the packing station and inhibits the pick-and-place sequence if no bags are queued for the packing robots. CUSTOMER APPLICATION In the food-processing industry, consumer products generally require secondary packaging – both for consolidation and for protection, before final dispatch. During confectionery production, individual bags of sweets travel by conveyor from bagging stations to a pick-and-place packing robot for secondary packaging, before passing on to the labelling and packing area. Ideally, product flow along the conveyor is continuous; in practice, interruptions occur from time to time as bagging machines require attention. In the absence of bagged products arriving at the secondary- packaging station, a plant-wide control system prevents operation of the pick-and-place robot to prevent miss-filling. Immediately prior to arrival at the secondary-packaging station, custom- formed guide rails align bags for packing. Space is limited and there is no easy access to both sides of the conveyor. A highly reliable non- contact sensor system was needed to detect the presence of bags as they approach the alignment rails; the system must inhibit the pick-and- place sequence if no bags are queued for packing.
Customer Solution Diffuse-mode photoelectric sensors from the Contrinex C23PA family of sensors are ideal for this application. These highly reliable devices contain both a transmitter and a receiver and do not require a separate reflector, instead relying on the reflective nature of the target. Space constraints are accommodated without compromise, thanks to a maximum sensing range of 3 to 1500mm. This is adjustable via a pre-set potentiometer or via IO-Link, the standardised point-to-point serial connection protocol. Immediately before the alignment rails, a single sensor is mounted beside the conveyor; positioning sensors is simple thanks to a range of adjustable mounting brackets. As each bag passes in front of the sensor, its presence triggers the device, sending a signal to the customer’s control system. A high-intensity red LED with a 15mm- diameter light spot at the selected 500mm sensing range ensures highly reliable detection of bags in real-time. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC-sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs.
APPLICATION - DETECTING BAGS OF SWEETS AT BUFFERING STATION
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CUSTOMER VALUES • Maximum sensing range 3mm to 1.5m. • Preventative maintenance ‘stability alarm’ – Output over IO-Link, or second switched output. • Switching frequency selectable between 500Hz and 5kHz via IO-Link • IO-Link interface included for free – Ideal for Industry 4.
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PRODUCT ADVANTAGES • Reliable, repeatable in-line detection on a non-contact basis. • Elimination of errors caused by previous mechanical sensors. • Increased productivity as stability alarm flags preventative-maintenance needs. • Single sensor accommodates a range of bag sizes without repositioning. • Remote adjustment via IO-Link reduces changeover time between products
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless- steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless- steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
APPLICATION - DETECTING SWEETS AT BUFFERING STATION
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
FILLING & LEVEL MONITOR APPLICATIONS Contrinex sensors are trusted on almost every type of filling machine.
Customer Solution Rugged photoelectric sensors with background suppression from the Contrinex C23 range are ideal for this application. A pinpoint red LED with a 10mm-diameter light spot at the maximum sensing range of 300mm ensures highly reliable detection of objects of almost any colour against light or dark backgrounds. These sensors are well suited to both the task and the environment. Immediately after packing, a single sensor is mounted centrally above the conveyor. As each carton passes below on its way to the sealing station, the sensor detects the top surface of the packed bags. If the height of the top layer falls outside preset limits, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Locating sensors optimally is simple thanks to a custom- designed range of multi-position mounting brackets. An operating range between 15mm and 250mm accommodates a variety of carton sizes without any need to reposition the sensor. A simple electrical adjustment via an onboard potentiometer suffices, while remote adjustment via IO-Link, a standardized point-to-point serial connection protocol, is available as standard at no extra cost for PNP versions.
A food-processing plant trusts Contrinex’s sensors to help it ensure plastic bottles, filled with liquid food products, are hermetically sealed and its customers kept safe. Prior to the containers being capped, a long-distance inductive sensor, positioned directly over the packaging line confirms the presence of an aluminium-foil seal over the top of every container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilized as seals for plastic containers filled with ketchup, mustard and other table sauces. At a food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging. From time to time, equipment malfunctions can occur and containers leave the sealing station without closures in place. If unsealed containers are not detected prior to capping, entire batches of product may require manual inspection, resulting in lost production, down-time or potential rejection by customers. An in-line sensor system inspecting each container could confirm the presence of a foil closure, rejecting any faulty items. Each production line processes containers in batches; successive batches may comprise filled containers of differing sizes. The system must accommodate containers whose heights vary by up to 20mm, without adjustment of sensors between batches as successive batches may comprise containers of differing sizes.
APPLICATION - POST-FILLING CHECK OF CLOSURES
APPLICATION - CONFECTIONERY BOX OVERFILL CHECK
During secondary packaging of bags of confectionery, manufacturers arrange bags in overlapping layers. Multi- axis pick-and-place packing robots align and pack layers of bags in preformed cardboard cartons. The filled cartons are conveyed to case-sealing stations. A highly reliable photoelectric sensor, mounted directly above the conveyor, senses the height of the top layer of bags in each carton before sealing and rejects insufficiently filled cartons CUSTOMER APPLICATION In the food processing industry, shingling, or overlapped layering, is a common technique for optimising space utilisation during secondary packaging operations. Confectionery, sealed in gusseted bags with predominantly triangular profiles, is packed in alternating, overlapping layers in preformed cardboard cartons. Once each carton is full, it passes to a case-sealing station prior to palletization and dispatch. Pre-aligned bags of confectionery arrive at the packing station in regularly spaced rows. At each station, a multi- axis pick-and-place packing robot lifts a row of bags, aligns it and lowers it into a preformed carton. Successive layers overlap each other, ensuring that space within the carton is fully utilised. Once the predetermined number of layers has been packed, the carton is conveyed to the sealing station. From time to time, one or more incorrectly formed layers occur. Individual bags may be missing from a row on arrival at the packing station, or may be damaged or misaligned. A non-contact sensor is needed to sense the height of the top layer of bags, rejecting any defective cartons. It must be reliable and require minimal maintenance.
Customer Solution Contrinex Extra Distance inductive sensors are ideal for this application. M30-diameter units from the range operate reliably at sensing distances up to 40mm; a single sensor thus accommodates the entire range of container heights. Robust construction with chrome-plated brass bodies and PBTP sensing faces ensures that these devices are suitable for a busy production environment. A single sensor, located immediately after the sealing station and positioned directly above the production line, provides reliable, repeatable and fast detection of the aluminium-foil closures. With a switching frequency of up to 100Hz, this Extra Distance unit is well suited for fast-moving production where high-speed sensing is required. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 cable connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC-sheathed cable. With an unmatched combination of 40mm sensing distance in an M30-diameter device, the customer can now test the entire range of containers without adjusting the sensor height between batches. Contrinex Extra Distance inductive sensors deliver exceptionally reliable test results at production-line speed, without interruption.
FIND OUT MORE - HERE ARE SOME SUGGESTIONS:
+ CUSTOMER VALUES • Reliable, repeatable in-line testing of a range of different-sized containers • Testing is completed without difficulty at production-line speed • Immediate identification of containers with missing closures • Elimination of manual inspection and potential batch rejection PRODUCT ADVANTAGES • Extended sensing distances up to 40mm • Unmatched combination of 40mm sensing distance in M30-diameter device + + CUSTOMER VALUES • Reliable, repeatable in-line quality checks on a non-contact basis • Improved quality arising from real-time detection of incorrectly packed cartons • Increased productivity as stability alarm flags preventative-maintenance needs • Single sensor accommodates a range of carton sizes without repositioning • Remote adjustment via IO-Link reduces changeover time between products PRODUCT ADVANTAGES • Maximum sensing range of 300mm with pinpoint red LED • Best-in-class background-suppression black/white behaviour • IO-Link connectivity available at no extra cost on PNP versions • Dual output with stability alarm +
Customer Solution Contrinex ultrasonic sensors are ideal for presence- and level-sensing applications, and a diffuse sensor from the Compact range (housing size M30) is an excellent choice for this application. Operating range for this metal-bodied, IP65-rated device is between 20cm and 130cm; detection is independent of the target’s color, shape, material or surface structure. Contrinex Compact ultrasonic sensors feature an integral S12 cable connector, allowing rapid disconnection and removal when required. The variable size and shape of meat residue makes it difficult for an uncompensated sensor to detect contamination consistently and reliably; potentiometer adjustment, provided by many manufacturers, is inadequate for this application. Contrinex CONPROG software for Windows®, connected via the APE-0000-001 PC interface, compensates perfectly. Using CONPROG, the operator characterizes the target area of the box during set-up, setting the exact operating parameters of the sensor and ensuring reliable detection. Sensor data is stored, allowing like-for-like sensor replacement without additional set-up. The sensor’s three-wire PNP normally-open output communicates directly with the customer PLC. On detection of a contaminated box, a mechanical diverter shunts the box to a separate conveyor for manual emptying.
APPLICATION - ULTRASONICS CHECK BINS ON WASH LINE
A Swiss meat-processing plant uses non-contact ultrasonic presence sensing to increase productivity and eliminate breakdowns when washing empty meat bins. A single ultrasonic sensor, mounted above the conveyor on which the bins travel, checks for meat residues, rejecting any contaminated bins before the wash station. Old, contact- based systems were unreliable, resulting in breakdowns and frequent interruptions to the washing process. CUSTOMER APPLICATION During production, an industrial meat-processing company conveys meat portions around its factory in food-grade plastic bins. After completion of each batch, empty bins are washed prior to reuse. Some bins contain sizeable pieces of meat which, if undetected, accumulate in the washing machine, causing blockages and breakdowns. The resulting interruptions to production are unacceptably frequent. A reliable sensor system must detect the presence of meat residues in bins as they travel along the conveyor. The sensor should identify all non-trivial residues and divert contaminated bins before they enter the washing station. The system should require little or no regular maintenance, and a non-contact sensor, suitable for a hygienic environment, is preferred. Old systems with spring-loaded wand-actuators in contact with the box are unreliable and require regular adjustment; the contact probes need frequent, time-consuming cleaning. The new system has to operate on a fit-and-forget basis.
+ CUSTOMER VALUES • Improved sensor reliability derived from exact characterization of target • Increased productivity arising from elimination of breakdowns • Reduced sensor maintenance resulting from non-contact operation • Industry-standard interface requires little modification to control systems PRODUCT ADVANTAGES • Characterised sensors detect targets of variable size and shape • Long-distance, non-contact operating principles • IP65 protection allows operation in hygienic environments • Rugged ultrasonic sensor with metal housing and metal cable connector +

TRANSPARENT APPS

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Helping you #MakeSenseofSensors
Customer Solution Diffuse-mode photoelectric sensors from the Contrinex C23PA family of sensors are ideal for this application. These highly reliable devices contain both a transmitter and a receiver and do not require a separate reflector, instead relying on the reflective nature of the target. Space constraints are accommodated without compromise, thanks to a maximum sensing range of 3 to 1500mm. This is adjustable via a pre-set potentiometer or via IO-Link, the standardised point-to-point serial connection protocol. Immediately before the alignment rails, a single sensor is mounted beside the conveyor; positioning sensors is simple thanks to a range of adjustable mounting brackets. As each bag passes in front of the sensor, its presence triggers the device, sending a signal to the customer’s control system. A high-intensity red LED with a 15mm-diameter light spot at the selected 500mm sensing range ensures highly reliable detection of bags in real-time. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs.
During high-speed production of retail bags, a confectionery manufacturer conveys individual bags of sweets to a pick- and-place packing robot for secondary packaging. A highly reliable diffuse-mode photoelectric sensor, mounted beside the conveyor, detects the presence of bags as they approach the packing station and inhibits the pick-and- place sequence if no bags are queued for the packing robots. CUSTOMER APPLICATION In the food-processing industry, consumer products generally require secondary packaging – both for consolidation and for protection, before final dispatch. During confectionery production, individual bags of sweets travel by conveyor from bagging stations to a pick-and- place packing robot for secondary packaging, before passing on to the labelling and packing area. Ideally, product flow along the conveyor is continuous; in practice, interruptions occur from time to time as bagging machines require attention. In the absence of bagged products arriving at the secondary-packaging station, a plant-wide control system prevents operation of the pick- and-place robot to prevent miss-filling. Immediately prior to arrival at the secondary-packaging station, custom-formed guide rails align bags for packing. Space is limited and there is no easy access to both sides of the conveyor. A highly reliable non-contact sensor system was needed to detect the presence of bags as they approach the alignment rails; the system must inhibit the pick-and-place sequence if no bags are queued for packing.
+ CUSTOMER VALUES • Reliable, repeatable in-line quality checks on a non-contact basis • Improved quality arising from real-time detection of incorrectly packed cartons • Increased productivity as stability alarm flags preventative-maintenance needs • Single sensor accommodates a range of carton sizes without repositioning • Remote adjustment via IO-Link reduces changeover time between products PRODUCT ADVANTAGES • Maximum sensing range of 300mm with pinpoint red LED • Best-in-class background-suppression black/white behaviour • IO-Link connectivity available at no extra cost on PNP versions • Dual output with stability alarm +