IQ-Sense replaces the connection of sensors via 24V digital input, by a point-to point connection with communications capabilities. The PLC can now exchange data with the sensors.

Advantages of the IQ-Sense technology compared to conventional sensor connections - Example for optical sensors

Conventional sensor connection techniques leave much to be desired. The sensors become more and more intelligent, but cannot communicate their "knowledge" to the controller. The elimination of this weak point is a feature our clients have long been asking for and the solution is now available for the first time with the IQ-Sense technology. The first delivery stage of IQ-Sense in connection with IQ-Sense reflection light barriers offers the following advantages:

1) Less wiring

Conventional connections of optical sensors to an ET 200 module (digital input channel) are made with 3-core cables (signal, +24V DC and M). If an additional diagnostic signal is to be transmitted from the sensor to the controller, an additional digital input and a 4-core cable are needed. The remote triggering of a teach-in procedure requires an additional 24V digital output and a 5-core cable. 
For all these functions the IQ-Sense technology only requires a simple 2-core cable with a minimum cross-section of 0.25mm² and a max. cable length of 50m. Shielded cables are not needed. Existing sensor cables can be re-used when switching to IQ-Sense. IQ-Sense reduces wiring work, because the two IQ-Sense wires can be connected at random to the corresponding IQ-Sense channel of the ET 200S electronic module.

2) Quicker mounting

Simplified adjustment of the sensor due to an integrated adjustment aid by means of LEDs during initial mounting and later replacement.

3) Quicker commissioning with IntelliTeach®

• Pre-adjustment of the sensor parameters or copying of the parameters set via teach-in to other modules or sensors, instead of laborious teaching of each sensor.
• Dynamic changing of parameters (e.g. setting the sensor range) via the control program and thus flexible adaptation of the parameters to the batch currently being produced. A standard function block "FB IQ-SENSE Opto" is available for this purpose for SIMATIC S7 PLCs (FAQs: Entry ID 9762434)

4) Higher plant availability
The IQ-Sense technology reduces plant downtimes to a previously unachieved low level.

• Messages and displays of operating states for preventive maintenance (e.g. a functional reserve warning in the case of dirt settlement on, or misadjustment of optical sensors). The programming work required in the case of conventional sensors falls away. In addition, IQ-Sense can provide messages concerning the operational status or error messages, in detailed plaintext, instead of as a group message display.
• Channel-specific system diagnostics, such as open wire (!!!absolutely new with optical sensors!), short-circuit, module or sensor failure, etc. 
• Quicker sensor replacement with automatic follow-up parameterization without renewed teach-in (adjustment). 
• Module replacement during operation and under voltage ("Hot swapping") is a system feature with 4DI IQ-Sense in ET 200S.

5) Anti-interference function

Avoidance of mutual interference between up to 16 sensors and thus prevention of errors.

6) Reduced varieties

The parameterization and diagnostic features of the IQ-Sense sensors enable many versions to be integrated into one IQ-Sense sensor. This reduces the number of stored items and simplifies the configuration.

Notes concerning configuration

The "4IQ-Sense" electronic module is 15mm wide and can be plugged into the following terminal modules:

• TM-E15S24-01
• TM-E15C24-01
• TM-E15S26-A1 (universal terminal module)
• TM-E15C26-A1 (universal terminal module)

More technical specifications are available from the ET 200S manual (free download from the Internet):

• 9715827
• 9716302

Configuration and parameterization 

• With STEP 7: 
  • integrated as from V5.1 SP3, or via GSD files
• With COM PROFIBUS: 
  • as from V5.1, ServicePack 2, Hotfix 1

The main areas of application for the IQ-Sense technology are systems and machines with:

• high requirements on availability
• high probability of the sensors influencing one another
• high flexibility and dynamic changing requirements of the sensor parameters