control cortinas

7/29/2019 Control Cortinas

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High-Resolution MINI-ARRAY Features Excelsathigh-speed,preciseprocess

monitoringandinspectionapplications

Acomprehensivecombinationofscanningmodesandoutputs:

10measurement(ScanAnalysis)modes 3scanningmethods

Beamblanking Selectablecontinuous,gatedorhost-

controlledscaninitiation Programmablehysteresisforhighandlow

limits Serialcommunicationoptions

Storablescanningprogramseliminatereprogrammingforrepeatedapplications

Non-volatilememorystoresalignmentsettings

AllmodelswithbothAnalogandDiscrete

outputs AnalogoutputNullsetting

Lowcost,comparedwithsimilarsystems

Precisionsensorshavea380mmto1.8m(15"to6')workingrange

Widefieldofview,easilyaligned

Alignmentroutineequalizesgainofeachbeamforreliable2.5mm(0.10")objectdetectionthroughoutthearray

HostcomputerorPLCmaybeusedtoinitiate

scansand/orprocessscandata Uniqueaddressesforupto15control

modulesononeEIA-485PartyLine

A-GAGE

High-Resolution MINI-ARRAY

Instruction ManualFor controllers with 2 analog and 2 discrete outputs

Printed.in.USA. 04/12 P/N 64118 rev.C

971410thAvenueNorthMinneapolis,MN55441Phone:763.544.3164 Fax:763.544.3213

Email:[email protected]

WARNING . . .Not To Be Used for Personnel Protection

ThesesensorsdoNOTincludetheself-checkingredundantcircuitrynecessarytoallowtheiruseinpersonnelsafetyapplications.Asensorfailureormalfunctioncancauseeitheranenergizedorde-energizedoutputcondition.ConsultyourcurrentBannerSafetyProductscatalogforsafetyproductswhichmeetOSHA,ANSIandIECstandardsforpersonnelprotection.

!


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P/N64118rev.B2

Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164


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3


P/N64118rev.B

Table of Contents


1. System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 SystemComponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 SystemFeatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.3 TypicalApplications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.1 EmitterandReceiverSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2 ControlModuleSpecifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3. Installation and Mechanical Alignment .. . . . . . . . . . . . . . . . . . . . . . . . . . . 123.1 EmitterandReceiverMounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2 ControlModuleMounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.3 Hookups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.3.1 EmitterandReceiverHookups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3.2 Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3.3 Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5. Control Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.1 CommunicationsSetup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1.1 PingRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1.2 FactorySettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2 SystemAlignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.1 Push-buttonAlignmentRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.2 SoftwareAlignmentRoutine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.2.3 Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.3 ProgrammingControlModuleResponse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5.3.1 SelectedControllerandSerialConnection. . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3.2 ControlModeSelection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3.3 ScanningMethod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.3.4 ScanAnalysisModeSelection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.3.5 AnalogOutputConfiguration(AnalysisModeAssignment). . . . . . . . . . . . 26 5.3.6 ZeroValue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.3.7 DiscreteOutputConfiguration(AnalysisModeAssignment). . . . . . . . . . . 28 5.4 SerialCommunicationwithaHostController . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.1 SerialDataTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.2 TransmissionType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.3 SerialOptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.5 TransferofPSFtotheControlModule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.5.1 SavingandRecallingPSFFiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5.2 PSFOutputAnalysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5.3 QuitandExit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6. System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1 DiagnosticsIndicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.2 DiagnosticsRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Appendix A: Data Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

A.1 HostModeCommandString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.2 SerialDataFormatandHeaderString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.2.1 ASCIIFormatDataTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A.2.2 BinaryFormatDataTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A.3 MaxMeasureModeCommandString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Appendix B: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38


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P/N64118rev.B

System Description

4


1. System Description

TheA-GAGEHigh-ResolutionMINI-ARRAY measuringlightscreenisidealforapplicationssuchason-the-flyproductsizingandprofiling,edge-guidingandcenter-

guiding,looptensioningcontrol,holedetection,partscountingandsimilaruses.

1.1 System Components

AtypicalA-GAGEHigh-ResolutionMINI-ARRAYSystemhasfivecomponents:ahigh-resolutionemitter/receiverpair,eachwithquick-disconnect(QD)connectors;oneoffourcompactcontrolmodules;andquick-disconnectcablestoconnectthem.SoftwareisincludedtointerfaceanyPC-compatiblecomputer(runningWindowsX, Vista,or 7)withthecontrolmoduleforSystemconfiguration.AhostcomputerorPLCmaybeusedtocontroland/orreceiveinputfromtheSystem.

Sensorsareavailablein12arraylengthsfrom163mmto1951mm(6.4"to76.8"),in163mm(6.4")increments,aslistedinthetableonpage5.TheemitterhastwocolumnsofinfraredLEDsspaced5mm(0.2")apart.Thecolumnsareseparatedby7.5mm(0.3")andarestaggeredfromeachotherby2.5mm(0.1").Thereceiverisconfiguredoppositetotheemitter,withtheidenticallengthandbeamspacing.Thishigh-resolutionsensorpairiscapableofdetectinga12.7-mmlongby2.54-mmdiameter(0.5"by0.1"dia.)cylindricalrod(heldperpendiculartothesensor).Thesensorshaveawidefieldofviewandareeasilyaligned,withaworkingrangeof380mmto1.8m(15"to6').

Eachofthefourversatilemicrocontroller-basedcontrolmodulesareconfiguredusingaPC-compatiblecomputerrunningWindows XP, Vista, or 7,andthesuppliedsoftware,viathebuilt-inRS-232interface.


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P/N64118rev.B

System Description

Emitter/Receiver

Model

MAHE64AEmitterMAHR64AReceiver

1626mm(64.0")

MAHE6AEmitterMAHR6A Receiver

MAHE77AEmitter

MAHR77AReceiver

1951mm(76.8")

MAHE13A EmitterMAHR13A Receiver


MAHE26A EmitterMAHR26AReceiver


MAHE38AEmitter

MAHR38A ReceiverMAHE45AEmitterMAHR45AReceiver




Array Length Y*

163mm(6.4")

325mm(12.8")

488mm(19.2")

650mm(25.6")

813mm(32.0")

975mm(38.4")

1138mm(44.8")

1300mm(51.2")

1463mm(57.6")

1788mm(70.4")

640

768

Total

Beams

64

128

192

256

320

384

448

512

576

704

Emitter and Receiver Models

Cables

Configure and monitor theSystem with the suppliedsoftware and anyPC-compatible computer(running WindowsXP,Vista, or 7), via an RS-232cable.

High-ResolutionReceiver

High-Resolution Emitter

DIN-Rail MountableControl Module

Figure 1-1. A-GAGE High-Resolution MINI-ARRAY System components


ControllerModel Solid-StateDiscrete Outputs AnalogOutputs

MAHCVP-1 2PNP (2)0-10VSourcing

MAHCVN-1 2NPN (2)0-10VSourcing

MAHCIP-1 2PNP (2)4-20mASinking

MAHCIN-1 2NPN (2)4-20mASinking

Quick-Disconnect Cables

Communication Cables

CableModel Description

Sensor Cables

QDC-515C 4.6m(15')Cable,straightQDconnector



Communication Cables

MASC 2m(6.5')DB9,straightRS-232cable

Control Module Models


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P/N64118rev.B

System Description

6

Figure 1-2. A-GAGE High-Resolution MINI-ARRAY System features

1.2 System Features

Built-infeaturessimplifytheoperationoftheA-GAGEHigh-ResolutionMINI-ARRAYsystem.High-resolutionemittersandreceivers,availablein12lengths,featuretwo

closelyspacedcolumnsofbeamstoprovideaprecise,high-resolutionlightscreenforexactingapplications.TheAlignmentroutineautomaticallyequalizestheexcessgainofeachbeamforreliable2.5-mm(0.10")objectdetectionthroughoutthearrayandstoresthisdatainnon-volatilememory.TheAlignmentroutineneednotbeperformedagainunlessthesensingapplicationchanges,oriftheemitterand/orreceiverismoved.Programmablebeamblankingaccommodatesmachinecomponentsorotherfixturesthatmustremaininormovethroughthelightscreen.Blankingmaybesetautomaticallyaspartoftheinitialsetup,orbyusingtheincludedconfigurationsoftware.

Built-indiagnosticprogrammingandeasy-to-seeindicatorsonthesensorsandthecontrolmodulemakealignmentandtroubleshootingeasy(Figure1-2).TheemitterhasaredLEDthatsignalsproperoperation.ThereceiverhasthreebrightLEDs:greensignalsthatthesensorsareproperlyaligned;yellowsignalsmarginalalignment;andredsignalsmisalignmentorablockedcondition.Thecontrolmodulehasfourstatusindicators:3redLEDssignaldiscreteoutput#1conducting(seesection5.3.5formoreinformationonoutputs),Alarmoutput(discreteoutput#2)conducting,andgatesignalreceived;agreenLEDsignalsthatthesensorsareproperlyaligned.AsegmentedLEDDiagnosticsIndicatorprovidesdetailedsystemstatususingsingle-digitcodes;aperiodintheindicatorwindowindicatesthepresenceofblanking.Akeytothediagnosticscodesisprintedonthesideofthecontrolmoduleforsimplifiedtroubleshooting.

TheA-GAGEHigh-ResolutionMINI-ARRAYSystemprovidesawideselectionofsensingandoutputoptions,including:measurement(scananalysis)modesandscanningmethodsthatcandeterminethetargetobjectslocation,overallsize,totalheightortotalwidth.Scanningmaybecontinuousorcontrolledbyahostprocesscontrolleroragatesensor.Upto15systemsmaybenetworked.

High-Resolution Emitter

DIN-Rail-Mountable Control Module

High-Resolution Receiver

HIGH RESOLUTION MINI-ARRAY CONTROLLER

ALIGNMENTSWITCH

POWER

POWER

DIAGNOSTICSINDICATOR

2 - TX3 - RX5 - COM

RS-232

MAHCVP-1

OUTPUT

ALARM

GATE

ALIGN

1

+

+

16-30V dc1A MAX

10-30VDCGATE

DOUT1

150mAMAX

0-10VOLTS

25mA(MAX)VOUT1

EMTR RCVR

2 3 4 5 6 7 8 9 10 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

F1+12VCOMDRNT/RT/R

BR BU BK WH

T X T X

+ 10-30VDC

ALIGN

0-10VOLTS25mA(MAX)

VOUT2+V

ALARM

150mAMAX

+V

7.6 mm (0.30")

2.5 mm(0.10")

5.1 mm(0.20")

Diagnostics Indicator

Alignment Button

Red Discrete Output #1 LED

RedOperationalLED

Green Alignment LED

Red Blocked LED

Yellow MarginalAlignment LED

Red Alarm (Discrete Output #2) LEDRed Gate LED

Green Align LED

RS-232 Port



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P/N64118rev.B

System Description


Figure 1-3. Typical applications for the A-GAGE High-Resolution MINI-ARRAY System

Log Profiling for Lumber Optimization Box Profiling

Maintaining Centering of Opaque Rolled Goods Inspection Applications

Supplied System SoftwareThesuppliedHRMAsoftwareprogram,usedtoconfigureeachSystemcontrolmodule,mayberunonanyPC-compatiblecomputerrunningWindowsXP, Vista, or 7..Themenu-drivenprogramwalkstheuserthroughthemanyscanningandoutputoptions.Afterthedesiredoptionsareselected,theusercansavethecombinationofselections

inaParameterSetupFile(PSF),andstoreitinthecontrolmodulesnon-volatilememory.AnynumberofPSFsmaybestoredinthesystemconfigurationcomputerandrecalledasneeded.

Thesoftwarealsoprovidesalignmentanddiagnosticsroutines.AnAlignmentscreendisplaystheindividualstatusofeachbeaminthelightscreen,aswellasthetotalnumberofbeamsintheSystem,andtotalsofbeamsblocked,madeandblanked.Built-insystemdiagnosticscanbeusedtoassessemitterandreceiverhardwareerrors.

1.3 Typical Applications


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P/N64118rev.B

Specifications

8


Environmental Rating

Minimum Object Sensitivity 2.5mm(0.1")

NEMA4,13(IP65)

Sensor Scan Time 1.8millisecondsto58.4milliseconds,dependingonscanningmethodandsensorlength;seeSection5.3.3fordetailedinformation

Power Requirements 12Vdc2%,suppliedbycontroller

Status Indicators Emitter: RedLEDlightstoindicateproperemitteroperationReceiver: Greenindicatessensorsaligned Yellowindicatesmarginalalignmentofoneormorebeams Redindicatessensorsmisalignedoroneormorebeam(s)blocked

Connections Sensorsconnecttocontrollerusingtwo5-conductorquick-disconnectcables(oneeachforemitterandreceiver),orderedseparately.Seepage5foravailablelengths.UseonlyBannercables,whichincorporateatwistedpairfornoiseimmunity.Cablesmeasure8.1mm(0.32")indiameterandareshieldedandPVC-jacketed.Conductorsare20gauge(0.9mm).Emitterandreceivercablesmaynotexceed75m(250')long,each.

Construction Aluminum,withblackanodizedfinish;acryliclenscover

Operating Conditions Temperature:0to+50C(+32to122F)Maximum relative humidity:95%at50C(non-condensing)

Emitter/Receiver Range 380mmto1.8m(15"to6')

2. Specifications

2.1 Emitter and Receiver Specifications

Certifications


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P/N64118rev.B

10.2 mm(0.40")

L3

38.1 mmSquare(1.50")

53.8 mm(2.12")

2.5 mm(0.10")

18.3 mm(0.72")

47.2 mm(1.86")

L1

71 mm(2.8")

R13 mm (0.5")Minimum Bend

L2

Figure 2-1. Emitter and receiver dimensions

With mounting bracket flanges inWith mounting bracket flanges out

Emitter/ReceiverModel

Housing Length Distance Between Bracket Holes

MAHE6AEmitter

MAHR6A Receiver236mm(9.3") 268mm(10.5")


399mm(15.7") 430mm(16.9")


561mm(22.1")


724mm(28.5") 756mm(29.7")


887mm(34.9") 918mm(36.2")

MAHE38AEmitterMAHR38A Receiver

1049mm(41.3")

MAHE45AEmitter

MAHR45AReceiver

1215mm(47.8") 1246mm(49.1")


1377mm(54.2") 1409mm(55.5")


1540mm(60.6") 1572mm(61.9")


1703mm(67.0") 1734mm(68.3") 1677mm(66.0")

1515mm(59.6")

1189mm(46.8")

1024mm(40.3")

861mm(33.9")

699mm(27.5")

536mm(21.1")

373mm(14.7")

211mm(8.3")


1865mm(73.4") 1897mm(74.7")


2028mm(79.8") 2060mm(81.1") 2003mm(78.8")

1840mm(72.4")

L1 L2 L3

593mm(23.3")

1081mm(42.6")

1352mm(53.2")

Specifications



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P/N64118rev.B

Specifications

10


Status Indicators

Power Requirements [email protected](typical:0.5A@16Vdc)

Output 1 (red): LightstoindicateDiscreteOutput#1isactiveAlarm (red): LightstoindicateDiscreteOutput#2isactiveGate (red): Lightstoindicate GATEinputisactiveAlign (green): LightstoindicateemitterandreceiverarealignedDiagnostics indicator: (Keyoncontrollersidelabel)IdentifiesSystemerrorsandstatus

Inputs Sensor input: Emitterandreceiverwireinparalleltofiveterminals.Gate input: Opticallyisolated,requires10to30Vdc(7.5kimpedance)forgatesignalRemote alignment input: Opticallyisolated,requires10to30Vdc(7.5kimpedance)foralignment

sequencesignal

Discrete (Switched) Outputs NPN outputs:OpencollectorNPNtransistorratedat30Vdcmax.,150mAmax.PNP outputs: OpencollectorPNPtransistorratedat30Vdcmax.,150mAmax.All discrete outputs: OFF-state leakage current:


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P/N64118rev.B

81.0 mm(3.19")

115.0 mm(4.53")

106.0 mm(4.17")

35.0 mm(1.38")

DIN mounting slot

Slot for M3.5 screws (2)5.5 mm(0.22")

69.0 mm(2.72 ")

5.0 mm(0.20")

96.0 mm(3.78")

Figure 2-2. Control module dimensions

Specifications



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P/N64118rev.B

Installation and Mechanical Alignment

12


3. Installation and Mechanical Alignment

3.1 Emitter and Receiver Mounting

BannerMINI-ARRAYemittersandreceiversaresmall,lightweight,andeasytohandleduringmounting.Themountingbrackets(supplied)allow30rotation.

Fromacommonpointofreference,makemeasurementstolocatetheemitterandreceiverinthesameplanewiththeirmidpointsdirectlyoppositeeachother.MounttheemitterandreceiverbracketsusingthevibrationisolatorsandM4Kepsnuts(allsupplied).SeeFigure3-1.StandardM4or#8-32boltsmaybesubstituted(andthevibrationisolatorseliminated)insituationswheretheemitterandreceiverarenotsubjectedtoshockorvibrationforces.Whiletheinternalcircuitsoftheemitterandreceiverareabletowithstandheavyimpulseforces,thevibrationisolatorsdampenimpulseforcesandpreventpossibledamageduetoresonantvibrationoftheemitterorreceiverassembly.

Figure 3-1. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting hardware

MountingSurface

M4 KepsNut (8)

M4 x 10 mmSlotted Hex Headwith Compression

Washer (2)

MountingBracket

Emitter orreceiver

Anti-VibrationMount (4)

MountingBracket

Washer

Nut

Studs: M4 x 0.79.5 mm (0.38") long


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P/N64118rev.B

NON-QD EndQD End

Min. R.

Full R (4)

4.8 mm (2)(0.19")

38.1 mm

(1.50")

6.4 mm R(0.25")

44.5 mm(1.75")

6.4 mm(0.25")

57.2 mm(2.25")

3.8 mm(0.15")

10.2 mm (2)(0.40")

30.5 mm(1.20")

34.8 mm(1.37")

11.9 mm(0.47")

Slots have clearancefor M4 bolts (supplied)

and allow 30 rotation

13.2 mm(0.52")

6.8 mm (2)(0.27")

3.0 mm(0.12")

24.6 mm(0.97")

53.8 mm(2.12")

Material: Cold Rolled SteelFinish: Black, Zinc Plated

Chromate Dip

Figure 3-2. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting bracket

dimensions



Mounttheemitterandreceiverintheirbracketsandpositiontheredlensesofthetwounitsdirectlyfacingeachother.Theconnectorendsofbothsensorsmustpointinthesamedirection.Measurefromoneormorereferenceplanes(e.g.thebuildingfloor)tothesamepoint(s)ontheemitterandreceivertoverifytheirmechanicalalignment.Ifthesensorsarepositionedexactlyverticalorhorizontaltothefloor,acarpenterslevel

isusefulforcheckingalignment.Astraightedgeorastringextendedbetweenthesensorsalsohelpswithpositioning.Alsocheckbyeyeforline-of-sightalignment.Makeanynecessaryfinalmechanicaladjustments,andhand-tightenthebrackethardware.SeeSection6forinformationonalignmentindicatorsandSection5forinformationontheuseofthealignmentsoftwarewhichissuppliedwiththecontroller.

3.2 Control Module Mounting

ThecontrolmodulemustbeinstalledinsideanenclosurewhichhasaNEMA(orIEC)ratingsuitablefortheoperatingenvironment.

MountingdimensionsforthecontrollerareshowninFigure2-2,onpage11.ThecontrolmoduleissuppliedwithM3.5hardwarefordirectmountingtoasurface,orthemodulemaybemountedontostandard35mmDINrail.


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P/N64118rev.B


14


POWER

1

+

+

16-30V dc1 A max

10-30V dcGATE

SIGNAL

+30V dc max

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

BROWN

BLUE

DRAIN(BARE)

BLACK

WHITE

DISCRETEOUTPUT#1

150 mAmax

EMITTER andRECEIVER CABLES

TX TX

DISCRETEOUTPUT#2 (ALARM)

+ 10-30V dc

ALIGN

RS-485

+30V dc max

150 mAmax

25 mAmax

0-10VANALOG

OUTPUT #2

25 mAmax

0-10VANALOG

OUTPUT #1

Figure 3-3. MAHCVN-1 hookup

POWER

1

+

+

16-30V dc1 A max

10-30V dcGATE

SIGNAL

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

BROWN

BLUE

DRAIN(BARE)

BLACK

WHITE

DISCRETEOUTPUT#1


TX TX

+ 10-30V dc

ALIGN

RS-485

150 mAmax

25 mAmax

0-10VANALOG

OUTPUT #2

25 mAmax

0-10VANALOG

OUTPUT #1


150 mAmax

Figure 3-4. MAHCVP-1 hookup

+30V dc max

POWER

1

+

+

16-30V dc1 A max

10-30V dcGATE

SIGNAL

+30V dc

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

BROWN

BLUE

DRAIN(BARE)

BLACK

WHITE



DISCRETEOUTPUT#1

+ 10-30V dc

ALIGN

Load

+16-30V

4-20 mAANALOGOUTPUT#2

4-20 mAANALOGOUTPUT#1

+16-30V

150 mAmax

150 mAmax

TX TX

RS-485

Load

Figure 3-5. MAHCIN-1 hookup

+16 30V dc+16 30V dc

POWER

1

+

+

16-30V dc1 A max

10-30V dcGATE

SIGNAL

4-20 mAANALOGOUTPUT #1

4-20 mAANALOG

OUTPUT #2

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

BROWN

BLUE

DRAIN(BARE)

BLACK

WHITE



+ 10-30V dc

ALIGN

Load Load

150 mAmax

DISCRETEOUTPUT#1

150 mAmax

TX TX

RS-485

Figure 3-6. MAHCIP-1 hookup

3.3 Hookups

RefertoFigures3-4,3-5,3-6,and3-7fortheappropriatehookupinformation.


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P/N64118rev.B

2 - TX3 - RX

5 - COM

RS-232

5 3 2


Serial CommunicationRS-232:AllA-GAGEHigh-ResolutionMINI-ARRAYSystemsmaycommunicatewitha

hostcomputerorcontrollerviaRS-232orRS-485serialprotocol.SeeSection5.3.1forselectablecommunicationsparameters.PrepareanRS-232cableusingamaleDB-9connectorwithconnectionsasshowninFigure3-8.

NOTE:DONOTuseanullmodemRS-232cable

RS-485: RS-485serialportislocatedatterminals#18(TX)and#19(TX).

DB-9 Pin # Function

2 Transmit(TX)

3 Receive(RX)

5 Ground(GND)

3.3.1 Emitter and Receiver Hookups

Emittersandreceiversconnecttogetherinparalleltoterminals#4through#8ofthecontrolmodule(identicalforallcontrolmodulemodels).SeeFigures3-3,3-4,3-5,and

3-6forwirecolorinformation.

3.3.2 Inputs

System Power: Connectasourceof16to30Vdc,ratedat1amporgreater,tocontrolmoduleterminals#1(+)and#2(-).Connectagoodearthgroundtoterminal#3toprovideelectricalandRFnoiseimmunitytotheSystem.

NOTE:Removepowerbeforemakingotherconnectionstothecontroller.

Gate Signal: Asourceof10to30Vdcswitchedtoterminals#12(+)and#13(-)

providesagatinginput(ifrequired).Thegatingvoltagetypicallyisswitchedbytheopen-collectoroutputtransistorofadcsensingdevice.ThegatesignalcontrolsscanningwhenoneoffourGateoptionsisselectedintheControlModeSelectionmenuofthePSFconfigurationroutine(seeSection5.3.2).

Align: Asourceof10to30Vdcswitchedtoterminals#14(+)and#15(-)providesaremotemeansofrunningtheautomaticalignmentandblankingroutines.TheswitchsequenceisidenticaltotheproceduredescribedinSection5.2.1fortheAlignment

switchonthefrontofthecontrolmodule.

Control ModuleAnalog Outputs

(Terminals #10 and 16)Discrete Outputs*

(Terminals #9 and 20)

MAHCVN-1Figure3-3

0to10VSourcing15mAmax.

NPNopen-collector30Vdcmax.150mAmax.

MAHCVP-1Figure3-4

0to10VSourcing15mAmax.

PNPopen-collector30Vdcmax.

MAHCIN-1Figure3-5

4to20mASinking

16to30Vdc

NPNopen-collector30Vdcmax.150mAmax.

MAHCIP-1Figure3-6

4to20mASinking

16to30Vdc

PNPopen-collector30Vdcmax.

150mAmax.*NOTE:DiscreteOutput#2islabeledAlarmonthecontrolmodule.Figure 3-8. DB-9 connections between the

control module and the PC

Trim braided shield flushwith cable

Trim foil shield flushwith cable

Uninsulateddrain wire

Figure 3-7. Emitter and receiver cablepreparation


NOTE:Thedrainwireistheuninsulated

strandedwirewhichrunsbetweenthe

braidedshieldandthefoilshield.Thefoil

shieldandthebraidedshieldshouldbe

removedatthepointwherethewiresexit

thecable.

3.3.3 Outputs


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P/N 64118 rev. B

Software Installation

16

Banner Engineering Corp. Minneapolis,U.S.A.

www.bannerengineering.com

Tel: 763.544.3164

4. Software Installation

The High-Resolution MINI-ARRAY software CD includes an installation routine that quickly and easily loads the MINI-ARRAY configuration programinto your computer. The High-Resolution MINI-ARRAY configuration program requires approximately 50 MB of hard disk space. Install as follows:

1. Use the Parameter Setup Software CD included with the controller, or download (www.bannerengineering.com) as required.

2. Insert the Software CD into the CD drive.

If the program does not auto-start, browse to your CD drive, click Setup.exe, then select START, then select RUN.

2. The Welcome dialog box will appear. Select Next, and follow the prompts in the dialog boxes as they appear.

4. The installation program then decompresses the files. A status dialog box monitors the progress of the installation.

5. An Installation Completed dialog box appears. Select OK. Reboot your computer for the changes to take effect.

After the software is installed, a MINI-ARRAY shortcut icon is placed on your desktop. Double-click on the MINI-ARRAY icon to launch the program, then

follow the configuration and setup procedures described in Section 5 of the primary manual.

Figure 4-1. MINI-ARRAY software installation: dialog boxes


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Control Module Configuration


Figure 5-1. Options menu, serial portselection

Figure 5-2. MINI-ARRAY menu

Figure 5-3. Screen showing the result of acompleted Ping routine

5. Control Module Configuration

TheA-GAGEHigh-ResolutionMINI-ARRAYcontrolmoduleiseasilyconfiguredusingaWindowsmenu-styleroutine;theconfigurationroutinerequirestheBanner-supplied

HRMAsoftwareandaPC-compatiblecomputer(runningWindows XP, Vista, or 7)AserialdataconnectionismadebetweenthecomputerandtheDB9connectoronthecontrolmodule.

5.1 Communications Setup

Afterinstallingthesoftware,attachtheserialcommunicationcablebetweenthecontrolmoduleandthePC.(NOTE:IfanRS-232interfaceisused,onlyonecontrolmoduleisallowedonthelineatanyonetime.)TheminimumconnectionstothecontrolmodulesDB-9connectorareshowninFigure3-8.

LaunchtheHigh-ResolutionMINI-ARRAYprogramandconfiguretheserialcommunicationsportofthePC.SelecttheOptionsmenufromtheHigh-ResolutionMINI-ARRAYmainmenu(seeFigure5-1).TheprogramsupportsserialcommunicationviatheCOM1-COM20.portofthecomputer.Highlightthedesiredserialporttoselectit(abulletwillappearnexttotheselectedoption),thenselectSave Settings on Exittostoretheserialportselection,ifitisnotalreadyON(abulletwillappearnexttotheoption,ifitisON).

Parityisselectedherealso:Even,OddorNone.

5.1.1 Ping Routine

ThePingroutinemustbeperformedduringSystemconfiguration,andbeforeanyDiagnostic,Alignment,orEditroutine.Theroutinepollsallcontrolmodulesonthecommunicationsline(one,inthecaseofthestandardRS-232line,orupto15modules,onanRS-485circuit).Itthenisusedtoselectanindividualcontrolmoduleforconfigurationoralignment.

Ifneeded,applypowertotheSystemcontrolmoduleandallowtheSystemtocompleteitspower-uproutine.Press F5oraccesstheMINI-ARRAYmenuandselectPingtoperformthePingroutine.AllconnectedcontrolmoduleswillthenidentifythemselveswithanIDvalueandbaudrate;theroutinetakesapproximately15to20seconds.AfterthePingisperformed,allvalidcontrolmoduleIDvalueswillappearinachartonthescreen,undertheirappropriatebaudrates(seeFigure5-3).ControlmodulesareidentifiedinthechartasX.PointtoavalidIDwiththemousepointerandclicktoselectacontrolmodule.SystemDiagnostics,Alignment,orEditroutinesmaynowbeperformedfortheselectedcontrolmodule.


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5.1.2 Factory Settings

Ofthe15availablecontrolmoduleIDvalues(AthroughO),thefactorysoftwaresettingisA.Selectablecommunicationbaudratesare9600,19200,and38400;the

factorysettingis9600.Seesection5.3.1forinformationonchangingthesesettings.

5.2 System Alignment

Theemitter/receiverpairshaveawidefieldofviewandareeasytoalign.Therecommendeddistancebetweentheemitterandreceiverrangesfrom15"to72".(Shortersensorseparationcanbeachieved;pleaseconsultfactoryfordetails.)TheAlignmentprocessshouldbeperformedatSysteminstallationandrepeatedeverytimeoneorbothofthesensorsismoved.AlignmentoftheSystemcanbespecifiedautomaticallyusingeithertheAlignmentroutineoftheconfigurationsoftwareortheAlignmentswitchonthecontrolmodulesfrontpanel.

TheSystemalsomaybealignedremotely,usingpins14and15ontheterminalblock.Apply10to30Vdcpowertothepins(seepage14)toapproximatethepush-buttonprocedure.(Forexample,applyinputsignalfor3secondstoaccessAlignmentmode.)

Makesurethesensorshavebeenwiredasshowninsection3.3.Applypowertothecontrolmoduleviaterminals#1and#2(16to30Vdc).TheDiagnosticsIndicatorwillshowthesensorsgoingthoughapower-uptest:firstthereceiver,thentheemitter.AfterthesensorshavebeentestedandtheSystemisreadyforservice,theDiagnosticsIndicatorwillshowor.;seeFigure5-4.

5.2.1 Push-button Alignment RoutineAtinstallationorwhenevertheemitterand/orreceiverismoved,theSystemshouldbere-aligned.PresstheAlignmentswitchonthecontrolmodulefrontpanelfor3seconds,afterwhichtimetheletterAwillappearontheDiagnosticsIndicator;theSystemislearningaclearcondition.Rotatethesensorsasrequired(butdonotchangethedistancebetweenthem).WhenthegreenAlignmentLEDisdisplayedonthecontrolmoduleandreceiver,thesensorsareadequatelyaligned.ToleaveAlignmentmode,againpresstheAlignmentswitchfor3seconds.

Duringthealignmentprocedure,thesystempollseachreceiverchanneltomeasureexcessgainandperformsacoarsegainadjustment.Whenthesystemexitsthealignmentprocedure,eachchannelssignalstrengthisstoredinnon-volatilememory.Thesystemisnowreadyforoperationanddoesnotrequirere-alignmentunlesstheemitterorreceiverismoved.

Figure 5-4. Diagnostics Indicator showing aclear condition

ALIGNMENTSWITCH

R


OUTPUT

ALA

RM

GAT

E

ALIGN

30V

150mA MAXEMTR RCVR

ALIGNMENTSWITCH

R


OUTPUT

ALARM

GATE

ALIGN

30V

150mA MAXEMTR RCVR

Denotes

Blanking

With Blanking OFF

With Blanking ON


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P/N64118rev.B

5.2.2 Software Alignment Routine

ThegreenLEDindicatoronthereceiverandalsoonthecontrolmodulecontinuously

displaysAlignmentstatus.Whenallunblankedbeamsareclear,thegreenAlignmentindicatorswillbeON.Tobetterunderstandblocked,clearandblankedbeams,launchtheAlignmentroutine(pressF8orselectAlignmentundertheMINI-ARRAYmenu).Thescreenwillshowthestateofallofthebeamchannels,groupedintosetsof16.

KeyinformationprovidedontheAlignmentscreenisthesensorsize,plusthenumberofbeamsblocked,made,andblanked.Thesensorsizeisgiventhetitleoftotal;thisreferstothetotalnumberofbeamchannelsinthearray.Thenumberofbeamsblockedisarunningtotalofblockedbeams,excludinganyblankedbeams.Themadevalueisacountofunblockedbeams.Theblankedvalueisacountofthenumberofbeamchannelsthatareblanked(channelsthatareignoredformeasurementmodeapplications;seesection5.2.3).

TheAlignmentscreenprovidesthefollowingfunctions:Start,Stop,Step,ClearBlankingFields,RestoreControlmoduleSettings,AutoBlanking,AbortAutoBlanking,SavetoFile,ReadFromFile,Cancel,OK,andEdit.Toaccessanyofthesesub-routinesfirstpressStop,thentheselectedoption.

StartcommandcausesthecontrolmoduletocontinuouslyscanandreportAllChannelData.Thisdataisusedtoupdatethestateofeachbeamchannel.

Stopcommandcausesthecontrolmoduletostopscanning.

Stepcommandproducesonescanandthenstopsuntilanothercommandisissued.

Clear Blanking Fieldscommandisaquickwaytoremoveblankingspecifications.

Restore Control Module SettingswillrecalltheblankingspecificationsineffectpriortoAlignment/Blankingbeingentered.

Auto Blankingcommandisusedtoscananddeterminewhichbeamsareblocked;blockedbeamsautomaticallybecomeblankedbeams.TheAutoBlankingvaluescanthenbeAcceptedorAborted.

Editisusedtocontroltheblankingspecificationsofanychannelmanually.Thisisusefulforaddinganynumberofblankedbeamchannelsaboveand/orbelowablankedobjecttoallowforvibrationorothermovementoftheobjecttobeignored.

BlankingspecificationscanbesavedandreadfromacomputerfileusingtheSave ToFileandRead From Filecommands.

Figure 5-5. Alignment screen




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5.2.3 Blanking

Ifamachinefixtureorotherequipmentwillcontinuouslyblockoneormorebeams,theaffectedbeamchannelsmaybeblanked.

TheBlankingoptioncausesthecontrolmoduletoignorethestatusofblankedbeamsformeasurementmodecalculations.Forexample,ifamachinefixtureblocksoneormorebeamsduringSystemoperation,theoutputdatawillbeincorrect;ifbeamsblockedbythefixtureareblanked,theoutputdatawillbecorrect.Blankingmaybeconfiguredusingthepush-buttonAlignmentswitchonthecontrolmodule,orbyusingthesystemsoftwareandacomputer.

Push-Button Blanking Setup RoutineTo specify blanking using the control modules Alignmentswitch,(seeFigure5.4)positiontheobjectorparttobeignoredinthepathofthebeamsbeforebeginningtheAlignmentroutine.PresstheAlignmentswitchfor3seconds;theDiagnosticsIndicatorwillshowtheletterA.PresstheAlignmentswitchagain,butthistimeonlymomentarily(about0.5secondsmax.).TheDiagnosticsIndicatorwillshowtheletterbtoindicateitisreadytolearntheblankingpattern.Again,momentarilypresstheAlignmentswitchtosettheblankingfields.Boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshowA.(theperiodfollowingtheAindicatesthatblankingisinuse).Thebeamsblockedduringtheroutinearenowblanked.ToreturntoRunmode,againpresstheAlignmentswitchfor3seconds.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing.(seeFigure5-4).

System Software Blanking Setup RoutineTo specify blanking using the System software,theprocedureissimilar.Positiontheobjecttobeblankedinthepathofthebeams(thiscanbedoneatanytimebeforebeginningtheblankingroutine).PerformthePingroutinetoselectthepropercontrolmodule,thenpressF8orselecttheAlignmentoptionfromtheMINI-ARRAYmenu.Fromthescreenmenu(Figure5-6),selectStop;theDiagnosticsIndicatoronthecontrolmodulewillshowtheletterA.SelectAuto Blanking (Figure5.7);theDiagnosticsIndicatorwillshowtheletterb.SelectAccept Auto Blanking;boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshowA.(theperiodfollowingtheAindicatesthatblankingisinuse).Thebeams

blockedduringtheroutinearenowblankedandappearastheletterBonthegridinsteadof0;ifyouwishtoblankadditionalbeams,usetheEditkeytomanuallysetadditionalblanking(seenextpage).ToleaveAlignmentmode,selectOK.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing.(seeFigure5-4).

Scanning Mode Limitations for Blanking:AllblankingfeaturesareavailablewithContinuousScanmode.Forsingle-anddouble-edgescan,blankingislimitedtofourblankingfields.Otherblankingfeaturesareignored.

Figure 5-6. Alignment screen, showing beams #1-11 blocked

Figure 5-7. Alignment screen, showing beams #1-11 blanked


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P/N64118rev.B



To accommodate parts or components that will move throughthe array,blankingmaybemanuallyadjustedforoneormoreindividualbeamchannels.AfterusingtheSystemsoftwaretospecifyblanking,selectEditfromtheAlignmentscreen;theDiagnosticsIndicatorwillcontinuetoshowtheletterbanda

gridwillappearonthecomputerscreen(Figure5-8).Thebeamsarenumberedfromthesensorscabledends,withthebeamclosesttothecablebeingbeam#1.Tosettheblankingfields,clickeachgridboxrepresentingabeamyouwishtoblank.

Clickingagainonablankedbeamchannelwillremovetheblankingspecification.Rowsofchannelscanbeselectedorclearedoftheblankingspecificationbyplacingthecursordirectlytotheleftoftherowtobeselectedandclickingthemouse;therowshouldbehighlighted.SelecttheBlankSelected(toaccepttheblankingstatus)orClear Selected(torejecttheblankingstatus)option.ToleaveAlignmentmode,selectOK.Boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshowA..WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing.(seeFigure5-4).

Figure 5-8. Edit channel blank state screen, showing beam #22 andbeams #35-42 blanked; beams #65-80 are highlighted,ready to be selected for blanking

5.3 Programming Control Module Response

TheParameterSetupFile(PSF)Configurationroutine(seeFigure5-9)isusedtoconfigurethecontrolmoduleforaspecificapplication.AccessthePSFConfigurationscreen(afterperformingthePingroutinetoselectacontrolmodule,section5.1.1)by

selectingEdit PSF (F4)fromtheMINI-ARRAYmenu.TheEditPSFprocessmayalsobeperformedwithnocontrolmoduleselected,toconfigureandsaveaPSFformultiplecontrolmodules.Insuchacase,somefieldsonthePSFConfigurationscreenwillnotbeaccessible.

Theprocessofconfiguringthecontrolmoduleinvolvesselectingamongoptionsforeachoftheparameterslistedinthissection,includingserialcommunication,controlmode,scanningmethod,scananalysismode,serialtransmission,andanalog/discreteoutputs.Theresultingcombinationofoptionscausesthecontrolmoduletoreactasrequiredfortheapplication,tochangesinthelightscreen.

TheconfigurationprocessproducesaParameterSetupFile(PSF).PSFfilesmaybesavedandretrievedascomputerfilesviatheFile Save PSFandFile Retrieve PSFcommands(seesection5.4.5).Onceconfigured,aPSFmaybesenttothecontrolmoduleviatheSend PSFcommand.Likewise,thePSFcurrentlyloadedintothecontrolmodulemaybedisplayedbyusingtheUpload PSFcommand.


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Figure 5-9. Use the PSF Configuration screen to program each control module individually

Serial TransmissionSpecifiesthetypeofdatatransmittedfromthecontrolmoduletoitshost

aftereachscan.Measurement Mode Result:DatatransmittedwillreflecttheAnalysisModeselections.All Mode:Transmitsalldata.Max. Meas. Mode: Sendsonlythelargestmeasurementineachmeasuringevent,todecreasetransmissionsizeandspeedresponse.Choosetosendwhenthearrayisclearorsendatthehostsrequest.Transmission Type: ASCIIorBinary,definestheformatinwhichthedatawillbesent.Serial Options:SuppressClearDataorSuppressHeadertodecreasetransmissionsizeandspeedresponse.

Analysis (Measurement)Mode Selection

Choosethemeasurementoptionthatbesttellsyou

thesizeand/orposition

ofobjectsastheyrelatetothearray.

Control Mode SelectionContinuous Mode:Thecontrol

moduleconstantlypollsthearrayforstatus.

Host Mode:Thecontrolmodulepollsthearrayforstatuswhenpromptedbyahostcontroller.

Gate Mode: Thecontrolmodulepollsthearrayforstatuswhen

promptedbyaninputfromaGatesensor.

Scanning MethodStraight scanpollseachbeam

sequentiallytodeterminethetargetobjectsoverallsize.Thisisthemost

accurateandprecisemeasurement,butalsothemosttime-consuming.

Single Edge scanrequiresthetargetobjecttoblockbeam1(closestto

thesensorscabledends),thenconductsatime-savingbinary

searchtohuntforthetargetsoverallheight(onevariableedge).

Double Edge scanconductsatime-savingsearchoftheentire

arraytohuntforthetargetsoverallwidth(twovariableedges).

Set Point andHysteresis SelectionAssignsthesetpointtodeterminewherewithinthearraytheoutput(s)willrespondandhysteresisvaluestosmoothoutputresponse.

Trigger/Trigger Channel NumberMaybeusedtotrigger(orgate)thescansequenceofanotherA-GAGE High-Resolution MINI-ARRAYcontroller;instraightscanningmode,itdefineswhenduringeachscandiscreteOutput#2willchangestate.

Scan #: (1-9)Analogoutputsareupdatedwithanaveragevalueofthedatareceivedduringtheselectednumberofscans;discreteoutputsrespondonlyifthereceiveddataisidenticalforalloftheselectednumberofconsecutivescans.

Analog and DiscreteOutput Assignment

Assignsananalysis(measurement)mode

toeachoutput.

Alarm:CausesthecontrolmoduletoturnondiscreteOutput#2whenevertheSystemdetectsasensingerrororiftheopticalsignalbecomesmarginal.

Selected ControllerIdentifiesthespecificcontrolmodulebeing

configured.

Serial CommunicationChangestheidentificationandbaudrateofthecontrollerbeingconfigured.

Zero ValueZeroValueisusedtospecifytheanalogoutputwhenthe

measurementmodevalueiszero.TheusercanspecifyavalueofLAST,NULL,orSPAN.

LAST:Outputholdsthelastnon-zerovaluebeforethelightscreenbecameclear.

NULL: Providestheminimumvalue.

SPAN:Providesthemaximumvalue.


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P/N64118rev.B

5.3.1 Selected Controller and Serial Communication

TheSelectedControllerboxdisplaysinformationaboutthecontrolmodulebeingconfigured.TwoofthesesettingsmaybechangedintheSerialCommunicationbox.

ThesettingsselectedanddisplayedintheseboxesarethoseusedtoidentifythecontrolmoduleduringthePingroutine(section5.1.1).

Controller ID(assignedaletter, AthroughO)isusedtoidentifyeachindividualcontrolmodulewhenmultiplediscrete-outputcontrolmodules(upto15)areconnectedononeEIA-485partyline.NOTE:AnalogoutputcontrolmodulesdonotofferRS-485communication;chooseanyIDletter(AthroughO)whenprogrammingananalog-outputcontrolmodule.

Baud Rateisthedatacommunicationratebetweenthecontrolmoduleandthecomputerusedforconfigurationandalsotheprocesscontroller.Choosefromthreevalues:9600, 19200,and38400.

Parity: SelectOdd,Even,orNone.AllcontrollersononeEIA-485partylineshould

havethesameparitysettings.

5.3.2 Control Mode Selection

Thecontrolmodedeterminesthemethodusedtocontrolscanningofthelightscreenarray(seeFigure5-11).Choosefromthreemaincontrolmodes:

ContinuousScanmode, SerialHostCommandmode,and Gatemode(whichitselfhasfouroptions)

In Continuous Scan Mode,thecontrolmodulebeginsanewscanassoonasitupdatestheoutputsfromthepreviousscan.Thisisthefastestscancontrolmethod;itisusedinmostanalogoutputapplicationsandwhenevercontinuousupdatingoftheoutputsisacceptable.

Host ModeallowsthecontrolmoduletocommunicatewithahostcomputerorcontrolmoduleviaRS-232(allmodels)orRS-485(discrete-outputmodelsonly)serialprotocol.ThehostdirectsthecontrolmoduletoscanondemandandreceivestheoutputdatafromthecontrolmoduleinbinaryorASCIIform.Baudratesof9600,19200,and38400areselectableintheSerialcommunicationsmenu(section5.3.1).(SeeAppendixAformoreinformationonHostmodedataformat.)

Gate ModeactivatesanopticallyisolatedexternalGateinputbetweenterminals12(+)and13(-)ofthecontrolmodule.TheGateinputhasimpedanceof7.5kandaccepts

a10to30Vdcsignal.AdcdevicesuchasaphotoelectricsensororopticalencodertypicallysuppliestheGateinput.Gateinputsignalsmustbegreaterthan150microsecondsinduration;thetimebetweensuccessiveGateinputsmustbegreaterthantheminimumscantimeforthelightscreenarray(seesection5.3.3forscantimeinformation).

Gatemodehasfouroptions: Gate ON: thecontrolmodulewillscanaslongasthegateisactive. Gate OFF: thecontrolmodulewillscanwheneverthegateisnotactive. Gate ON/OFF: thecontrolmodulewillscanonceforeachgatetransitionfromONtoOFF. Gate OFF/ON:thecontrolmodulewillscanonceforeachgatetransitionfromOFFtoON.

Figure 5-11. Control Mode selections(PSF Configuration screen)

Figure 5-10. Selected Controller and SerialCommunicationselections (PSF Configurationscreen)




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P/N64118rev.B


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Banner Engineering Corp. Minneapolis,U.S.A.

www.bannerengineering.comTel:763.544.3164

5.3.3 Scanning Method

Thecontrolmodulemaybeconfiguredforoneofthreescanningmethods(Figure5-12): Straightscan

Single-Edgescan Double-Edgescan

Straight Scanisthedefaultmodeinwhichallbeamsarescannedinsequencefromthebottomend(cableend)tothetopendofthearray.Thisscanningmethodrequiresthelongestscantimesandprovidesthesmallestobjectdetectionsize(2.5mm,0.1"diameter).

Single-Edge Scanisusedtomeasuretheheightofasingleobject.Agoodapplicationforthisscanningmethodisboxheightmeasurement.ForSingle-EdgeScan,theSystemalwaysactivatesthefirstbeamchannel(nearestthecableend,orbottom).Ifthefirstbeamisblocked,thesensorwillperformabinarysearchtohuntforthelastbeamblocked.Single-EdgeScanworksasfollows:

1. Thereceiverscansonlythebottombeamuntilthatbeamisblocked.

2. Whenthebottombeamisblocked,thesensorlookstoseewhetherthemiddlebeamisblockedormade(unblocked).

3. Ifthemiddlebeamismade(unblocked),thesensorchecksthebottomquarterbeam;ifthemiddlebeamisblocked,thesensorchecksthetopquarterbeam.(Thisiscalledabinarysearch;seeFigure5-13.)

4. Thisroutinecontinuestonarrowthefielduntiltheedgeisfound.

Notethatthereceiveralwayschecksthebottombeamfirst,andonlyifthatbeamisblockeddoesthebinarysearchcontinue.Therefore,Single-EdgeScanwillnotworkininstanceswhereanitemthatdoesnotblockthefirstbeamistobemeasured.Single-EdgeScanisalsoineffectiveiftheobjectdoesnotpresentacontinuousblockedpattern.Inotherwords,Single-EdgeScanisusedforsingle,solidobjectsthatblockthefirstbeam.

Figure 5-12. Scanning Method selections(PSF Configuration screen)

DIAGNOSTICS

E rrorNo.

E rrorTy pe

ErrorNo.

ErrorType

SystemOK

4

EmitterError

1

Align/blank

5

Se rialComm

2

Output Short

6

EEPROM

3

E/ RMismatch

7

CPUE rror

4

Rece iv erError

8

Null/Span

1PO

WER

2 -TX

3 -RX

5 -COM

ALIGNM

ENT

SWITC

H

D IAGNO

STIC S

INDICA

T OR

RS-232

MAHCN-

1

HIGH R

ESOLUT

IONM IN

I-ARRAY

CONTRO

LLER

23

45

67

89

1011

121 3

1 415

1617

1819

20

1

+

NC

NC10-30Vd

c

GATE

NC

TXTX

+12V

BR

EMTR

RCVR

BU

BK

5W ir es

W H

30V

150mAM

AX

OUTPUT#1

COMDRN T/

R T/ R

16-30Vdc

1AMAX

POW ER

23

45

67

89

1011

1213

1415

1617

1819

20

OUTPUT

ALARM

GATEA

LIGN

+

F1

30V(MAX

)

150mAM

AX

ALARM

10-30Vdc

ALI GN

RS- 485

+

High-Resolution

Emitter

MAHCN-1

Control ModuleHigh-Resolution

Receiver

Beam #1 of 64

Blocked

Beam #48

Clear

Beam #32

Blocked

Beam #44

Clear

Beam #40

Blocked

Beam #42

Blocked

Beam #43

Blocked

Step #2Step #1 Step #3

Step #4 Step #5 Step #6 Step #7

Figure 5-13. Finding an edge using a binary search


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P/N64118rev.B

Double-Edge Scanisusedtodetecttwoedgesofasingleobject,forexample,boxwidthmeasurements.Double-EdgeScanrequirestheselectionofastepsize:2,4,8,16or32beams.Thesensorusesthestepstoskipoverbeams.Double-EdgeScanworksasfollows:

1. Thesensoractivatesbeam#1(thebeamclosesttothesensorcableend).2. Thesensoractivatesthenextbeam,determinedbythestepsize.(Forexample,if

thestepsizeis2,beam#3isnext;ifthestepsizeis8,beam#9isnext.)

3. Aslongastheactivatedbeamisunblocked(ormade),thesensorwillcontinuethesteppingroutineuntilablockedbeamisfound.

4. Whenablockedbeamisfound,abinarysearchisconductedtofindtheobjectsbottomedge.

5. Whenthebottomedgeisfound,thesensorbeginssteppingagainthroughthearrayuntilthesensorfindsthenextunblockedbeam.

6. Abinarysearchisagainperformedtofindthesecondedge.

Notethatthisscanningmethodsacrificesobjectdetectionsizeforspeed.Similarto

Single-EdgeScan,Double-EdgeScanhassomerestrictions:theobjectshouldprovideasolidobstruction;thesizeoftheobjectwilldeterminethemaximumstepsize(Figure5-14).

Sensorresponsetimeisafunctionofsensorlengthandscanningmethod.TypicalscantimesareshowninFigure5-15.

Step Size

Number of Beams

MinimumObjectDetectionSize

5mm(0.2")

10mm(0.4")

20mm(0.8")

40mm(1.6")

80mm(3.2")

Maximum Scan Times (in milliseconds)

ArrayLength

StraightScan

Single-EdgeScan

Double-Edge Scan

Step2 Beams

Step4 Beams

Step8 Beams

Step16 Beams

Step32 Beams

163 mm

(6.4") 5.8 1.8 3.4 2.7 2.5 2.6

325 mm(12.8")

10.6 1.9 8.1 5.1 3.6 3.0 2.7

488 mm(19.2")

15.0 2.1 11.5 6.8 4.5 3.4 3.0

650 mm(25.6")

20.1 2.1 14.9 8.5 5.3 3.9 3.2

812 mm(32.0")

24.9 2.1 18.3 10.1 6.1 4.2 3.5

975 mm(38.4")

30.0 2.1 21.7 11.8 7.0 4.7 3.6

1138 mm(44.8")

34.5 2.1 25.0 13.5 7.9 5.1 3.8

1300 mm(51.2")

39.3 2.1 28.4 15.2 8.7 5.5 4.1

1626 mm(64.0")

48.0 2.3 35.1 18.6 10.4 6.4 4.5

4.8

1788 mm(70.4")

53.6 2.3 38.5 20.3 11.2 6.8 4.7

Figure 5-14. The effect of step size onminimum object detection size

Figure 5-15. The effect of sensor length and scanning method on scan time (typical)



NOTE:Scantimesareexclusiveofserialcommunicationtransmissiontimes.

1463 mm(57.6")

44.0 2.2 31.8 16.9 9.5 5.9 4.3

1951 mm(76.8")

58.4 2.3 41.9 21.9 12.1 7.2 4.9

2 4 8 16 32


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26

5.3.4 Scan Analysis Mode Selection

Thecontrolmodulemaybeprogrammed,ifdesired,foranyoneortwoofsevenScanAnalysis(measurement)Modes.Eachselectedmodemaybeassignedindividuallyto

anoutput(seesection5.3.5or5.3.6).Thebeamsinthearrayarenumberedinsequence,withbeam#1locatedatthecabledendoftheemitterandthereceiver.

Beam Location Modes First Beam Blocked (FBB): ThecontrolmoduleidentifiesthelocationoftheFirst

BeamBlocked.

First Beam Made (FBM):ThecontrolmoduleidentifiesthelocationoftheFirstBeamMade(unblocked).

Last Beam Blocked (LBB):ThecontrolmoduleidentifiesthelocationoftheLastBeamBlocked.

Last Beam Made (LBM):ThecontrolmoduleidentifiesthelocationoftheLastBeamMade(unblocked).

Middle Beam Blocked (MBB):ThecontrolmoduleidentifiesthelocationoftheMiddleBeamBlocked,midwaybetweenthefirstandlastbeamsblocked.

Beam Total Modes Total Beams Blocked (TBB): Thecontrolmoduletotalsthenumberofblocked

beams.

Total Beams Made (TBM): Thecontrolmoduletotalsthenumberofmade(unblocked)beams.

Contiguous Beams Blocked (CBB):Thecontrolmoduleidentifiesthelargestnumberofconsecutivelyblockedbeams.

Contiguous Beams Made (CBM):Thecontrolmoduleidentifiesthelargestnumberofconsecutivelymadebeams.

Transitions (TRN):Thecontrolmodulecountschangesfromblockedtoclearand

cleartoblocked.Forinstance,ifbeams6-34areblocked,thenthereisaclear-to-blockedtransitionfrombeam5tobeam6,andablocked-to-cleartransitionfrombeam34tobeam35.Transitionmodecanbeusedtocountobjectswithinthearray.

TheAnalysisMode(s)programmedmaybeassignedtoanyoneoftheavailableoutputs(seeFigure5-18).EachoutputcanbesetforMEAS1, MEAS2, MEAS1InvertedorMEAS2 Inverted.

5.3.5 Analog Output Configuration (Analysis Mode Assignment)

Analogoutputs#1and#2mayeachbeassignedtooneoftheanalysismodesdescribedinsection5.3.4.WhentheselectedScanAnalysisModeinvolvesfirstor

lastbeamblockedormade(unblocked),theassignedoutputwillvaryinproportiontothebeamnumberidentifiedduringascan.WhentheScanAnalysisModeinvolvestotalbeamsblockedormade,thatassignedoutputwillvaryinproportiontothetotalbeamscountedduringascan.

Notethatthepull-downmenususedforassignmentoftheScanAnalysisModestotheanalogoutputsincludetwoInvertedselections.WheneitherMEAS1 InvertedorMEAS2 Invertedisselected,thatanalogoutputwilldecreaseasthemeasurementmodevalueincreases.Aninvertedoutputwillbeatfullscale(Spanvalue)whenthescananalysisvalueiszero;andatmaximumscananalysisvalue,theoutputwillbeattheNullvalue.

Figure 5-18. Assigning an Analysis Mode toeach Analog Output(PSF Configuration screen)

Figure 5-17. Examples of MINI-ARRAY scananalysis modes

Figure 5-16. Scan Analysis Mode Selection(PSF Configuration screen)

Last Beam Made (LBM)First Beam Made (FBM)

Receiver

Emitter

8

16

24

32

40

48

Last Beam Blocked (LBB)First Beam Blocked (FBB)

Receiver

Emitter

8

16

24

32

40

48

Total Beams Made (TBM)Total Beams Blocked (TBB)

Receiver

Emitter

8

16

24

32

40

48

InLastBeamBlockedmode,

lastbeamis#43of48

InFirstBeamBlockedmode,

firstbeamis#15of48

InLastBeamMademode,

lastbeamis#37of48

InFirstBeamMademode,

firstbeamis#26of48

InTotalBeamsMademode,

34of48possiblebeamsare

made

InTotalBeamsBlockedmode,

14of48possiblebeamsare

blocked



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P/N64118rev.B

TheNullandSpanrangesmaybeadjustedasfollows:

Toreadthenewvaluesonthemeter,clickonNullorSpan Update.ClickontheOKbuttontosavethenewsettingsandreturntheprogramtothePSFConfigurationscreen.ClickingontheCancelbuttonreturnstheprogramtothepreviouslysavednullandspansettings.

NOTE:NullandSpanarefactorysettospecifiedvaluesandusuallyrequirenochanges.

Scan #Providesawaytosmoothoutputresponseandavoidunstableanalogoutputconditions.Themenuallowsselectionoffrom1to9scans(seeFigure5-20).Foranalogoutputs,ifscan#issetatmorethan1,thescananalysisvalueisaveragedforalloftheselectednumberofconsecutivescans,preventingdipsandspikesintheoutputs.

Fortotalbeamvalues(TBBandTBManalysismodes),programmingofblankedbeams(section5.2.3)willaffecttheproportionalanalogoutputs.Blankedbeamsareignoredbothinthenumberofblockedormadebeamsandthetotalnumberofbeams.Forexample,ifa64-beamarrayhas20blankedbeamsand22oftheremaining44beamsareblocked,theoutputvalueswillbeatmid-range.

5.3.6 Zero Value

Zerovalueisusedtospecifytheanalogoutputwhenthemeasurementmodevalueiszero.TheusercanselectananalogoutputofLAST,NULL,orSPAN.

LAST: Outputholdsthelastnon-zerovaluebeforethelightscreenbecameclear.NULL: ProvidestheminimumvalueSPAN: Providesthemaximumvalue.

TheNull/SpanConfigurationscreen(Figure5-19),maybeusedtoadjustthezeroandfullscalereadingforeitheranalogoutput.TodisplaytheNull/SpanConfigurationscreclickontheNull/SpanbuttonatthebottomofthePSFConfigurationscreen(Figure5-Eachoutputisindependentandmustbeadjustedseparately.AdjusttheNullandSpanvalueseitherbymovingtheslidebars,orbyenteringanewvalueonthekeyboard.

To Measure:Analog Voltage Output:Connectthevoltmeterbetweenterminals10or16(+)and17().

Analog Current Output:Connecttheammeterbetweenterminals10or16()and1(+).

AnalogOutput Type

Null Span

Minimum Maximum Minimum Maximum

Voltage 10mV 2.3V 4.8V 10.1V

Current 3.9mA 7.8mA 11.9mA 20.2mA

Figure 5-19. Null/Span Configuration screen

Figure 5-20. Scan # (PSF Configurationscreen)

Figure 5-21. Zero Value (PSF Configurationscreen)



NOTE:WhenintheNull/Spanscreen,thecontrollerwillhaveadiagnosticcodeof8.


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5.3.7 Discrete Output Configuration (Analysis Mode Assignment)

Discreteoutputs#1and#2(Alarm)mayeachbeindividuallyassignedtooneoftheScanAnalysisModesprogrammedinsection5.3.4(seeFigures5-16and5-22).

NexttoeachdiscreteoutputassignmentmenuareLowandHighSet Pointboxes.Thenumberineachboxidentifiesabeaminthearray(beam#1beingclosesttothecabledendoftheemitterandthereceiver).TheLowandHighSetPointsmaybechangedbyclickingonaboxandenteringanewnumber.

WhentheselectedScanAnalysisModeinvolvesfirstorlastbeamblockedormade(unblocked),theassignedoutputwillenergizewhenthebeamidentifiedduringascanfallswithintherangeofthesetpoints.WhentheScanAnalysisModeinvolvestotalbeamsblockedormade,thatassignedoutputwillenergizewhenthevalueoftotalbeamscountedduringascanfallswithintherangeofthesetpoints.

Notethatthepull-downmenususedforassignmentoftheScanAnalysisModestothediscreteoutputsincludetwoInvertedselections.WheneitherMEAS1 InvertedorMEAS2 Invertedisselected,thatdiscreteoutputwillde-energize(turnOFF)wheneverascananalysisvaluefallswithintherangeofthesetpoints.

Hysteresisvaluesforeachendofthesetpointrangemayalsobeset(Figure5-22).Hysteresisdeterminestheamountofchangethatmustoccurateachsetpoint(HighandLow)tocausetheassociatedoutputtochangestate.Hysteresispreventsunstableoutputconditionswhenthescananalysisvalueexactlymatchesoneofthesetpoints.ThedefaulthysteresissettingisonebeamlessthantheLowSetPointandonebeammorethantheHighSetPoint.

Scan #Providesanotherway,inadditiontohysteresissettings,tosmoothoutput

response.Outputsareupdatedonlyaftertheselectednumberofidentical(withinthehysteresislimits)scans.Themenuallowsselectionoffrom1to9scans.Fordiscreteoutputs,thescananalysisvaluemuststayeitherinsideoroutsidethehysteresislimitsforalloftheselectednumberofconsecutivescans,inorderfortheoutputtorespond.SeeFigure5-23.

Alarm and TriggerDiscreteoutput#2(only)hastwoadditionaloptions:AlarmandTrigger.

Alarm:Output#2energizeswhenevertheSystemdetectsasensorerror(suchasadisconnectedcable)orwhenevertheexcessgainofoneormorebeamsbecomesmarginal.

Trigger: canbeusedtogateasecondcontrolmodulewhenContinuousScanMethodisalsoused.Whenthecontrolmoduleisinstraightscanningmode,Trigger ChannelNumberdefinesthebeamnumberduringascanatwhichthetriggeroutputwilloccur(Figure5-23).TheTriggeroutputisa100microsecond(0.0001sec.)pulse.Ifthecontrolmoduleissetforsingleordoubleedgescan,theTriggerpulsewillcomeattheendofthescan(Trigger Channel Numberwillbeignored).

Figure 5-23. Scan # (PSF ConfigurationScreen)

Figure 5-24. Trigger Channel

Figure 5-22. Assigning an Analysis Mode to each Discrete output(PSF Configuration screen). Alarm and Triggeroutput options are available only for DiscreteOutput #2.


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5.4 Serial Communication with a Host Controller

ThecontrolmodulecommunicateswithahostprocesscontrollerviaRS-232orRS-485protocolandatthebaudratespecifiedintheSerialCommunicationsbox

(section5.3.1).TheSystemprovidesanumberofdatatransmissionoptions.

5.4.1 Serial Data Transmission

TheserialtransmissionportionofthePSFConfigurationscreenactivatestheserialport(s),specifiesthedataformat,andprovidesdatasuppressionoptions.Thesesettingsarerequiredtoallowacontrolmoduletocommunicatewithahostcomputerorprocesscontroller.IfNo Serial Communicationisselected(thedefaultsetting),theserialport(s)willnottransmitsensingdata.

Measurement Mode Result: datatransmittedwillbethevaluesoutputfortheScan

AnalysisModeselections.UptotwoScanAnalysisModeselectionscanbeactive.

ALL Mode: thestatusofeachbeaminthelightscreenarraywillbetransmittedforeach scan. InALLmode,blankedchannelsaretransmittedasunblocked(orclear)beams.

Max Meas Mode: thecontrolmodulerecordsthemaximummeasurementvalueregisteredwhilethelightscreenisblocked.Thatdatamaybetransmittedtothehosteitherwhenthearrayisclearattheendofthesensingevent(selectSend On Clear),orwhenpromptedbythehost(selectSend On Request).Thismodereducestheamountofserialdatasent.

5.4.2 Transmission Type

Transmissiontypedefinestheformatinwhichdataissent.TheASCIIoptioncausesthecontrolmoduletosenddatainthreeASCII-codedbytes.TheBinaryoptioncausesdatatobesentinbinaryformat,reducingtheamountofdatapermeasurementmodefromthreebytestotwo.Formoreinformationonthedataformats,refertoAppendixA.

Figure 5-25. Serial Data Transmissionoptions (PSF Configurationscreen)




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5.4.3 Serial Options

TheSerialOptionsboxprovidestwooptions:Suppress Clear DataandSuppressHeader.

Suppress Clear Dataprovidesonemethodtoreducetheamountofdatabeingtransmittedbythecontrolmodule,accomplishedbynotsendingdatawhennoobjectisdetected.Thecontrolmoduletransmitsserialdataonlywhenoneormoreunblankedbeamsofthelightscreenarrayareblocked.Whenthearraygoesfromblockedtoclear,dataissentoneadditionaltime,indicatingtheclearcondition.

Suppress Headerisusedtopreventtransmissionofthethree-byteidentificationstring(headerstring)associatedwitheitherASCIIorBinarydataformats.Theheaderstringconsistsoftwobytesatthestartofthedata,andaterminationbytetomarktheendoftheserialtransmission.SeeAppendixAformoreinformationonserialdataformats.

5.5 Transfer of PSF to the Control Module

AftermakingalloftheselectionsinthePSFConfigurationscreen,thePSFmaybesenttothecontrolmodulebyclickingtheSend PSFbutton(seeFigure5-26).ThiscommandloadsthePSFintothenon-volatilememoryofthecontrolmodule,andautomaticallyoverwritesthecurrentPSF.TheprogramwillconfirmthatthePSFwasaccepted,orwillnotifytheuserofchangesrequiredtothePSF.

TocheckthevaluesofthePSFcurrentlyloadedintothecontrolmodule,selectUploadPSF.ThecurrentPSFwillbedisplayedonthePSFConfigurationscreen.

Figure 5-26. PSF Output options (PSF Configuration screen)


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System Diagnostics


5.5.1 Saving and Recalling PSF Files

ToplacethedisplayedPSFintoafilethatcanberetrievedatanytime,selectFileSave PSF (Figure5-26).WhenaskedifyouwanttosavethePSFtoafile,selectYes.

AsubscreentitledFileSavewillappear(Figure5-27).Overtype*.psfintheFileNameentryboxwiththenameofthefiletobestored(upto8characters),plusthe.psfextension;thenselectOK(orpressEnter).ThePSFwillbestoredontheselecteddrive(defaultisc:)andtheprogramwillautomaticallyreturntothePSFConfigurationscreen.

ToretrieveafiledPSF,selectFile Retrieve PSF.TheFileBoxsubscreenwillappear(Figure5-28).SelectthedesiredPSFfromtheFileNamelistandselectOK(orpressEnter).TheselectedPSFwillloadtothePSFConfigurationscreen,anditcanthenbeloadedintothecontrollerusingtheSend PSFcommand.

5.5.2 PSF Output AnalysisToviewactivityinthearrayinresponsetothecurrentlyloadedPSF,selectExecute(Figure5-26).TheMeasurementOutputscreenwillappear(Figure5-29);selectRun.Thetablewilldisplaythestatusfortheselectedmeasurementmode(s),includingthePresentvalueandtheHighandLowvaluesfortheRunperiod.

SelectStoptofreezethedata.SelectSteptoinitiateasinglescanofthearraytosimulateasnapshotofwhatisviewedbythearrayattheinstantthatStepisselected.

UseoftheExecutecommandisespeciallybeneficialfortestingtheresponseofagatedsystem.RunsimulatestheContinuousScanningmode,andStepsimulatesagateinputcommand.

5.5.3 Quit and Exit

ToclosethePSFConfigurationscreen,selecteitherQuitorExit (Figure5-26).SelectingQuiterasestheEditPSFScreenandsendstheuserbacktotheMainWindow;thepresentPSFScreenvaluesarenotretained.TheExitcommandissimilartotheQuitcommand,excepttheuserwillbepromptedtosavetheconfigurationvaluestoaparametersetupfile(PSF).

Figure 5-27. FileSave subscreen of thePSF Configuration screen,accessed with the File SavePSF command

Figure 5-28. FileBox subscreen of the PSFConfiguration screen,accessed with the FileRetrieve PSF command

Figure 5-29. Measurement Output subscreen ofthe PSF Configuration screen,accessed with the Executecommand


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32


6. System Diagnostics

Systemdiagnosticsmaybeperformedusingthestatusanddiagnosticsindicatorsonthecontrolmoduleandsensors,orbyusingtheDiagnosticssoftwareroutine,ora

combinationofthetwo.

6.1 Diagnostics Indicators

NOTE:StatusindicatorsappeartofreezeifthecontrollerhasbeenconfiguredforGateorHostmode(Section5.3.2),andnosignalispresenttocauseascanupdate.

DIAGNOSTICSError No. Error Type/Action

System is OK

A / b Align / blank Status

1 Output Short Checkoutputload&wiring

2

E / R Mismatch

Systemmustusesamelengthemitterandreceiver

3Receiver Error Checkreceivercable Replacereceiver

4Emitter Error Checkemittercable Replaceemitter

5 Serial Comm Checkserialcable

6EEPROM ReconfigurePSF Replacecontrolmodule Reconfigureblanking

7 CPU Error Replacecontrolmodule

8 Null / Span Status

Figure 6-2. Key to System DiagnosticsIndicator codes

RedOperationalLED

Green Alignment LED

Red Blocked LED

Yellow MarginalAlignment LED

High-Resolution

Emitter

High-Resolution

ReceiverDIN-Rail-MountableControl Module

HIGH RESOLUTION MINI-ARRAY CONTROLLER

ALIGNMENTSWITCH

POWER

POWER


2 - TX3 - RX5 - COM

RS-232

MAHCVP-1

OUTPUT

ALARM

GATE

ALIGN

1

+

+

16-30V dc1A MAX

10-30VDCGATE

D OUT 1150mA MAX

0-10VOLTS25mA (MAX)

V OUT 1

EMTR RCVR

2 3 4 5 6 7 8 9 10 1 1 12 1 3 14 1 5 16 1 7 18 1 9 20

F1+12VCOMDRNT/RT/R

BR B U BK WH

T X T X

+ 10-30VDC

ALIGN

0-10VOLTS25mA (MAX)

V OUT 2+V

ALARM150mA MAX

+V

Diagnostics Indicator

Alignment Button

Red Discrete Output #1 LEDRed Alarm (Discrete Output #2) LED

Red Gate LEDGreen Align LED

RS-232 Port

Figure 6-1. A-GAGE High-Resolution MINI-ARRAY System diagnostics and status indicators

Bright,easy-to-seeLEDindicatorsonbothsensorsandonthefrontpanelofthecontrolmoduleprovideanongoingdisplayofthesystemsoperatingstatus.

Control Module:OUTPUT:(red)displaysthestatusofDiscreteOutput#1.

ALARM: (red)displaysthestatusofDiscreteOutput#2.Thisoutputmaybeassignedtoananalysismode,oritmaybeusedasaSystemDiagnosticsalarmorasaTriggeralarmtogateanotherA-GAGEHigh-ResolutionMINI-ARRAYSystem.

GATE:(red)displaysthestatusoftheGateinput.

ALIGN: (green)indicatesproperemitter/receiveralignmentandaclear,unblockedlightscreen.ThisindicatorisONwheneitherthegreenorboththegreenandyellowLEDsofthereceiverareON.


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Diagnostics Indicator: Thisbright,segmentedLEDdisplayonthecontrolmodulefrontpanelindicatesoneof10Systemstatusconditions,plusthepresenceorabsenceofblanking.(BlankingONcausesaperiodtoappearintheDiagnosticsIndicatorwindow,inadditiontotheSystemsotherstatuscondition.)SeeFigure6-2forthekeytotheseerrortypesandstatusconditions;thischartisalsolocatedonthesideofthecontrol

module.

Emitter:OPERATIONAL:(red)LEDindicatespowertotheemitterisON,andunitisoperational.

Receiver:BLOCKED: (red)LEDindicatessomeofthearraybeamsareblocked.

MARGINAL:(yellow)LEDindicatesthatarrayalignmentismarginal.

ALIGNMENT: (green)LEDindicatesthatarrayalignmentissatisfactory.

Toimprovealignment,adjustthepositionoftheemitterandreceiveruntilthegreenLEDlights,makingsurethatnounblankedbeamsareinterrupted.Thenuseoneofthemethods

inSection5.2torealignthesystem.

6.2 Diagnostics Routine

EmitterorreceiverproblemsmaybefurtherdiagnosedusingtheDiagnosticsroutineincludedwiththeMINI-ARRAYsoftware.LaunchtheprogrambyselectingDiagnosticsundertheMINI-ARRAYmenu(Figure5-2)orbypressingF2.

TheDiagnosticsscreen(Figure6-3)displaysthesizeofeachemitterandreceiver(expressedinthenumberof64-element

boardsitcontains)anditsfunctionalstatus(orstate).Ifanerrorhasoccurred,thespecificproblembeamchannelisidentified.Additionally,ifthereisaproblemwithanemitterorreceivercableconnection,aNo Responsemessageisdisplayed

TheDiagnosticsroutinealsodisplaysthepartnumberanddatecodeofthecontroller,informationthatmaybeusefuliffactory-assistedtroubleshootingbytelephoneisrequired.

Figure 6-3. Diagnostics screen, accessible from the MINI-ARRAY menu


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Appendix A: Data Transmission

34



A.1 Host Mode Command String

Asdiscussedinsection5.3.2ofthismanual,thecontrolmodulehasthreecontrolmodeoptions:continuous,gate,andhost.Hostmoderequiresaserialtransmissionstringfromaseparatedevice,typicallyaPCorprocesscontroller.TheserialtransmissionmediumcanbeeitherRS-485orRS-232.

WhenHostcontrolmodeisselected,thehostprocesscontrollerinitiatesscansusingacommandstring.Thecommandstringisathree-bytemessage,consistingof:

Controlbytewithdecimalvalue248,

ControllerID(theidentificationofaspecificcontrolmoduleonthestring,indicatedbyoneof15ASCIIlettersAthroughO,andspecifiedinthePSF),and

Scaninitiationbyte(ASCIIletterS).

Thecommandstringisfurtherdefinedasfollows:

/*the below C code will define an array called msg that will contain the Host Scan Command */

unsigned char msg[3]; /*declare three byte unsigned character array using C language */

msg[0]=248; /*control byte */

msg[1]=65; /*assume the controller ID is the letter A */

msg[2]=83; /*assume initiation byte which is the ASCII letter S */

Thehosttransmitsthisthree-bytemessageatthedefinedbaudrate.Theformatisonestartbit,onestopbit,evenparity,andeightdatabits.Whenthecontrolmodulereceivesthismessage,itinitiatesascan(assumingHostmodeisselected)andthen

updatesitsoutputsasrequired.ThecontrolmodulethenwaitsforthenextHostCommandmessagebeforeinitiatinganotherscan.

A.2 Serial Data Format and Header String

Theprogrammedmeasurementmodeormodesdeterminethetypeofinformationthatisseriallytransmitted.ForexampleifMeas1issetforFBBandMeas2issetforLBB,thenthedatatransmittedtothehostcontainsthevaluesofthefirstandlastbeamblocked.TheAllmeasurementmodeprovidesthestatusofallbeamstothehost.

Inadditiontomeasurementmodeinformation,thedatatransmissionalsocontainsa

two-bytestartstringandaterminationbyte.Thestartstringconsistsofafirstbytethatdoesnotchange,followedbythecontrollerID.Thefirstbytevalueisahex1Cor28decimal.Attheendofthestring,thecontrolmodulewillplaceaterminationbyte.TheterminationbyeistheASCIIcharacterforalinefeed(hexvalue0A).ThesethreebytescollectivelyarecalledtheSerialHeaderstring.

Figure A-1. Serial Transmission options(PSF Configuration screen)


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A.2.1 ASCII Format Data Transmission

TherearetwowaystouseASCIIformattorepresentdata.Theoneuseddependsuponwhichmeasurementmodesareselected.

For ALL measurement mode,eachdatabyteispresentedinaneight-bitASCIIformatthatconveysthestatusoffourconsecutivechannels(fourconsecutivebeams).Eachsubsequentbyteconveysthestatusofthenextfourchannels,untilthestatusofeverychannelisreported.TheallowabledatavaluesforAllmeasurementmodeareASCIInumbers0to9andASCIIlettersAtoF.Inthetable,a0representsanunblockedbeamchannel,and1representsablockedchannel.

Forexample,assumethata64-channelsystemhasbeenconfiguredfortheAllmeasurementSerialtransmissionoption.Channels1through4areblocked,asischannel63.Theserialstringstartswith0x1c,andtheID(assumeanA)followedby16ASCIIvaluesandterminatedwith0x0A.Thestringwouldappear:

0x1c, A, F, 0,0, 0,0, 0,0, 0,0, 0,0, 0,0, 0,0, 0,4, 0x0a

Thestringshowsthatbeams1through4areblocked,asisbeam63.Allotherbeamsareunblocked.Iftheuserhadrequestedsuppressionoftheheader,then0x1c,A,andthe0x0awouldhavebeendeleted.

For transmitting Measurement mode data,usethreeASCIIbytestorepresenteachmeasurementmode.Forexample,ifMeas1isFBB,Meas2isLBB,themeasuredvaluesare6and120,andthecontrollerIDisB,thedatastringisasfollows:

0x1c B, 0, 0, 6, 1, 2, 0, 0x0a

AswithALLmode,theheaderandcleardatacouldbesuppressed.Forcleardatasuppression,thecontrolmodulesendsthestatusofaclearconditiononlyonthefirstclearscan.Afterthat,thecontrolmodulewillcontinuetoscanbutwillnottransmit

datauntilthesensorisagainblocked.

A.2.2 Binary Format Data Transmission

SimilartoASCIIformat,binaryformatmaybeusedtorepresentdataintwoways.OnemethodinvolvestheAllDatatransmissionmode;theother,Measurementmode.

For All Data transmission mode,thecontrolmodulerepresentsthestatusofeightconsecutivedatachannelsforeachbyte.Eachbitofeachbyteisdirectlyrelatedtothestatusofanindividualchannel.Thefirstdatabyterepresentschannels1through8;theseconddatabyterepresentschannels9through16.Thebitpatternforthefirstand

seconddatabytesisasshowninFigureA-3.

Foreachbitposition,1representsablockedbeamand0representsanunblockedbeam.

Forexample,fora64-channelsystemwithbeams1-6blocked,beam43blockedandbeams62-64blocked,thedatatransmittedfromcontrolmoduleAisasfollows:

0x1c, A, 0xFC, 0x00, 0x00, 0x00, 0x00, 0x20, 0x00, 0x07, 0x0A

Thisstringwouldhavethestartbyte,controllerID,followedbytheeightdatabytesandterminatedwiththe0x0A.Theheaderbytesmaybesuppressedifnecessary.



Figure A-2. ASCII data values

Definitions for ASCII Data Values

FortheALLmeasurementmode

Character Ch 4 Ch3 Ch2 Ch1

F 1 1 1 1

E 1 1 1 0

D 1 1 0 1

C 1 1 0 0

B 1 0 1 1

A 1 0 1 0

9 1 0 0 1

8 1 0 0 0

7 0 1 1 1

6 0 1 1 0

5 0 1 0 1

4 0 1 0 03 0 0 1 1

2 0 0 1 0

1 0 0 0 1

0 0 0 0 0

First Data Byte Second Data Byte

ChannelBit

Position ChannelBit

Position

1 7 9 7

2 6 10 6

3 5 11 5

4 4 12 4

5 3 13 3

6 2 14 2

7 1 15 1

8 0 16 0

Figure A-3. Binary data values


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36


For Measurement mode analysis,thebinaryformatusestwodatabytesforeachmeasurementmode.(Ifwehaveonemeasurementmode,thentherearetwodatabytes.Fortwomeasurementmodes,therearefourdatabytes.)

Forexample,assumethatcontrolmoduleBisconfiguredforonemeasurementmode

(FBB),andthevalueis78.Thestringfromthecontrolmoduleisasfollows:

0x1c, B, 0x00, 0x4E, 0x0A.(atotaloffivebytes)

or

0x00, 0x4E(atotaloftwobyteswithSuppressHeaderoption)

NowassumethatcontrolmoduleBisconfiguredforFBBandLBBwithvaluesof74and303,respectively.Thestringfromthecontrolmoduleisasfollows:

0x1c,B, 0x00, 0x4A, 0x01, 0x2F, 0x0A(atotalofsevenbytes)

or

0x00, 0x4A, 0x01, 0x2F(atotaloffourbyteswithSuppressHeaderoption)

A.3 Max Meas Mode Command String

MaxMeasModecausesthecontrolmoduletoretainthemaximummeasurementvaluesforagivenobject.ThesevaluesaretransmittedeitherimmediatelyafterthecontrolmoduleisclearedorwhenpromptedbytheHost.TheMaxMeasModeCommandStringisafour-bytestringthatappearsasfollows:

Controlbytewithdecimalvalue248

ControllerID(oneof15ASCIIlettersAthroughO,asspecifiedinthePSF)

MaxMeasCommandTransmit(ASCIIletterT).

Terminationbytewithdecimalvalue13

Thecommandstringisfurtherdefined:

/*the below C code will define an array called msg which will contain the Max Meas Mode

Command String*/

unsigned char msg[4]; /*declare four byte unsigned character array using C language */

msg[0]=248; /*control byte */

msg[1]=65; /*assume the controller ID is the letter A */

msg[2]=84; /*assume initiation byte which is the ASCII letter T */

msg[3]=13; /*termination byte */

Whenthehostsendsthisstring,thecontrolmodulesendsthemaximumvaluesstoredfromthepreviousscannedobject.Ifthesensorispresentlyscanninganobjectwhenthemessageissent,thecontrolmodulewillgivethemaximumvaluesforthepresentobject.


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Appendix B: Glossary

38


Appendix B: Glossary

Blanked Beam: Abeamthatisignoredbythereceiver,asaresultofablankingprogrambeingappliedtoit.Beams(orgroupsofbeams)areblankedwhenacomponentorfixturewillremaininormovethroughthelightscreenarray;blankingtheaffectedbeamspreventsthecomponentorfixturefromcausingfalseoutputs.

Blocked Beam: Abeamthatisobstructedbetweentheemitterandthereceiver,andisnotblanked.

Clear Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasamadeorunblockedbeam).

Excess Gain: Ameasurementoftheamountoflightfallingonthereceiverfromtheemitteroverandabovetheminimumamountrequiredforoperation.A-GAGEHigh-ResolutionMINI-ARRAYemittersandreceiversautomaticallyperformanAlignment

proceduretoequalizetheamountofexcessgainateachelementalongthearray.

Host: AcomputerorprocesscontrollerthatcontrolsandreceivesinputfromtheHigh-ResolutionMINI-ARRAYSystem,and/orotherequipmentandsystemswithinafactory.

Made Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasanunblockedorclearbeam).

Unblocked Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasamadeorclearbeam).


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Banner Engineering Corp Limited Warranty

Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following the date of shipment. Banner Engineering Corp.

will repair or replace, free of charge, any product of its manufacture which, at the time it is returned to the factory, is found to have been defective during the warranty

period. This warranty does not cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product.

THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED (INCLUDING, WITHOUT LIMITATION,

ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE,

COURSE OF DEALING OR TRADE USAGE.

This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP. BELIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL, CONSE-

QUENTIAL OR SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT, WHETHER ARIS-

ING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY, NEGLIGENCE, OR OTHERWISE.

Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any obligations or liabilities relating to any product

previously manufactured by Banner Engineering Corp.

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