DF-G2 High Speed Expert™ Dual Display Small Object Counter
Contents
1. Dynamic TEACH is best used when a machine or process may not be stopped for teaching The sensor learns during actual sensing conditions taking multiple samples of the light and dark conditions and automatically setting the threshold at the optimum level see Figure 6 on page 9 Darkest Taught Lightest Taught Condition Condition i Sensor positions i threshold midway between taught conditions 1 I 1 1 Output ON Darkest Position Most Light no signal saturated signal Figure 6 Dynamic TEACH Light Operate shown The output ON and OFF conditions can be reversed using the LO DO switch see LO DO Switch in Top Panel Interface on page 4 Dynamic TEACH 9 See Troubleshooting on page 12 for more explanation of the Offset displayed after the Light SET method P N 178061 Rev C www bannerengineering com Tel 1 763 544 3164 9 DF G2 High Speed Expert Dual Display Small Object Counter Follow these steps to perform a Dynamic TEACH K NOTE TEACH Selection must be programmed to dYn tcH see Program Mode on page 5 1 Enter Adjust Mode RUN PRG ADJ SET Button 10 Set Mode switch to ADJ Display Red Signal Level Green 11 F n A Threshold Remote Input No action required sensor is ready for Dynamic TEACH method EEO Ea 2 Enter Dynamic TEACH Method Action Result on 1234 dYn SET Button Click the SET rocker button C Display Flashes dYn tch then holds T Remote Input Si2. oO 10 30V dc 1 2 3 4 5 no connection Programming Programming NO N 0 Top Panel I nterface Opening the dust cover provides access to the top panel interface The top panel interface consists of the RUN PRG ADJ mode switch LO DO switch SET rocker button dual red green digital displays and output LED RUN PRG ADJ KoE o RUN PRG ADJ Mode Switch The RUN PRG ADJ mode switch puts the sensor in RUN PRG Program or ADJ Adjust mode RUN mode allows the sensor to operate normally and prevents unintentional programming changes via the SET button PRG mode allows the sensor to be programmed through the display driven programming menu see Program Mode below ADJ mode allows the user to perform Expert TEACH SET methods and Manual Adjust see Adjust Mode below LO DO Switch The LO DO switch selects Light Operate or Dark Operate mode In Light Operate mode the output is ON when the sensing condition is above the threshold for Window SET the output is ON when the sensing condition is inside the window In Dark Operate mode the output is ON when the sensing condition is below the threshold for Window SET the output is ON when the sensing condition is outside the window SET Rocker Button The SET rocker button is a 3 way button The positions are engaged by rocking the button left right The SET position is engaged by clicking down the button while the rocker is in the middle p
3. signal Figure 5 Light SET Light Operate shown Light SET Follow these steps to perform a Light SET cS Note TEACH Selection must be programmed to Lt SEt see Program Mode on page 5 1 Enter Adjust Mode Method Action Result RUN PRG ADJ SET Button 7 Set Mode switch to ADJ Display Red Signal Level Green ar Threshold Remote Input 8 No action is required sensor is ready for Light SET method EEO A 2 SET Sensing Condition 7 SET Button 0 04 seconds lt Click lt 0 8 seconds Remote Input 0 04 seconds lt T lt 0 8 seconds 8 www bannerengineering com Tel 1 763 544 3164 P N 178061 Rev C DF G2 High Speed Expert Dual Display Small Object Counter Method Action Result e Present sensing condition e Click the SET rocker button Threshold Condition Accepted Present sensing condition T Displays read Lt SEt then alternate u u with o 9 e Single pulse the remote input ee epee eee Sensor SET Button Remote Input Threshold Condition Not Accepted Displays read Lt SEt then alternate FAIL with minimum Offset for sensing condition Sensor returns to Adjust mode 3 Return to RUN Mode Method Action Result RUN PRG ADJ SET Button Move Mode switch to RUN Display Red Signal Level Green Threshold Remote Input No action required sensor returns to RUN mode automatically annj EET e Teaches on the fly e Establishes a single switching threshold
4. com Tel 1 763 544 3164 5 DF G2 High Speed Expert Dual Display Small Object Counter Factory Default Settings Threshold 3700 typical TEACH Selection Window SET Response Speed Standard 250 us Offset Percent 2 Totalizer Counts OFF Totalizer One Shot OFF Dynamic Event Stretcher 50 Display Readout Numeric ECO disabled Normal Orientation Adjust Mode Sliding the RUN PRG ADJ mode switch to the ADJ position allows the user to perform Expert TEACH SET methods e Sets window thresholds that extend a programmable offset above and below the presented condition All other conditions lighter or darker cause the output to change state e Recommended for applications where a product may not always appear in the same place or when other signals may appear e See Program Mode in the user s manual for programming the Offset Percent setting to increase decrease the window size A single sensing condition is presented and the sensor positions window thresholds a programmable offset above and below the presented condition In LO mode Window SET designates a sensing window with the Output ON condition inside the window and the Output OFF conditions outside the window see Figure 3 on page 6 Sensing Window e Sensor positions i window thresholds g i a programmable i i offset from the i presented condition Jutpu Output ON Darkest Condition Most Light no signal Presented saturated si
5. 061 Rev C DF G2 High Speed Expert Dual Display Small Object Counter Installing the Fibers Follow these steps to install glass or plastic fibers Move forward a to release the fibers 1 Open the dust cover 2 Move the fiber clamp forward to unlock it 3 Insert the fiber s into the fiber port s until they stop 4 Move the fiber clamp backward to lock the fiber s 5 Close the dust cover Fiber Clamp Fiber Receiver Port Fiber Emitter Port Fiber Adapters K NOTE If a thin fiber with less than 2 2 mm outer diameter is used install the fiber adapter provided with the fiber assembly to ensure a reliable fit in the fiber holder Banner includes the adapters with all fiber assemblies TO FIBERS N lt te SENSOR Fiber Outer Diameter mm Adapter Color Black Red No adapter needed When connecting coaxial type fiber assemblies to the amplifier install the solid core fiber to the LED emitting port and the multi core fiber to the PD receiving port for most reliable detection RECEIVER Multi core fiber gt lt Single core fiber 0 wie ee gt TRANSMITTER P N 178061 Rev C www bannerengineering com Tel 1 763 544 3164 3 Wiring Diagrams PNP Models DF G2 High Speed Expert Dual Display Small Object Counter NPN Models K NOTE Open lead wires must be connected to a terminal block A e lt Ww S me 3 10 30V dc gt
6. DF G2 High Speed Expert Dual Display Small Obj ect Counter more sensors more solutions Quick Start Guide Advanced sensor with dual digital displays for small object counting applications For complete technical information about this product including dimensions accessories and specifications see www bannerengineering com and search 178236 A WARNING Not To Be Used for Personnel Protection Never use this device as a sensing device for personnel protection Doing so could lead to serious injury or death This device does not include the self checking redundant circuitry necessary to allow its use in personnel safety applications A sensor failure or malfunction can cause either an energized or de energized sensor output condition Overview Output LED LO DO Switch RUN PRG ADJ Mode Switch LO DO RUN PRG ADJ Lever Action Fiber Clamp Red Signal Level Green Threshold SET Rocker Button Figure 1 DF G2 Model Features Models Outputs Connector DF G2 NC 2M Single NPN plus Health Mode output 2 m 6 5 ft cable 5 wire DF G2 PC 2M Single PNP plus Health Mode output DF G2 NC Q5 Single NPN plus Health Mode output 150 mm 6 in PVC pigtail M12 Euro QD connector 5 pin DF G2 PC Q5 Single PNP plus Health Mode output DF G2 NC Q7 Single NPN plus Health Mode output Integral M8 Pico QD connector 6 pin DF G2 PC Q7 Single PNP plus Health Mode output 1 Connector options e A model with a QD connect
7. bled the total counts value increments to 9999 and then starts over at 0 Changing any operational setting causes the total counts value to reset to 0 Program Mode PROGRAM MODE Mode Switch gt To scroll through menu lists Press or To enter a choice list or to select and save Click SET To exit a choice list without saving Press and hold SET for 2 seconds rocker button Menu gt ZE um um dYn Es to PRG diSPrEAd FctYdEF Click SET Click SET Click SET Click SET Click SET Click SET Click SET Click SET to enter choice list to enter choice list to enter choice list to enter choice list to enter choice list to enter choice list to enter choice list to enter choice list Vv v v v vy v v e By siti Cat Corr Corr__ Corr Lt SEt ole 1 ms Cas pect Ta GeO el eet al RRt ez diSP 1234 diSP 123 Eco 1234 Eco 123P display flips 180 EZL dS P 100 Pct dEZL dS P bEZL 039 d gL 097 Click SET to select and save a choice in any list Return to Menu List BJ yES Press and hold SET to exit choice list without saving on display represents a w on display represents a m Figure 2 Program PRG mode allows the following settings to be programmed in the DF G2 P N 178061 Rev C www bannerengineering
8. e 720 mW Current consumption lt 30 mA at 24 V dc 12 us Supply Protection Circuitry a ie Protected against reverse polarity and transient over voltages 50 if Delay at Power Up 80 us 500 milliseconds max outputs do not conduct during this time c i onstruction Output Configuration Black ABS polycarbonate alloy UL94 V 0 rated housing clear 1 current sinking NPN or 1 current sourcing PNP output depending on polycarbonate cover model plus 1 Health Mode output Environmental Rating Output Rating IEC IEC IP50 NEMA 1 100 mA maximum combined load derate 1 mA per C above 30 C ON state saturation voltage NPN 1 5 V PNP lt 2V Temperature 0 ee rnn T i j Storage Temperature 20 C to 85 C 4 F to 185 F Output Protection Humidity 90 at 60 C maximum relative humidity non Protected against output short circuit continuous overload transient condensing over voltages and false pulse on power up Operating Conditions Certifications Connections PVC jacketed 2 m or 9 m 6 5 ft or 30 ft 4 wire integral cable or integral 4 pin Pico style QD or Pico style 150 mm 6 in pigtail QD or Euro style UL 150 mm 6 in pigtail QD c US LISTED Ind Cont Eq 3TJJ 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 charg
9. e 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 EXCLUSI VE 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 ENGI NEERING CORP BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS EXPENSES LOSSES LOSS OF PROFITS OR ANY INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT WHETHER ARISING I N 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 BANNER more sensors more solutions www bannerengineering com Tel 1 763 544 3164
10. ects e Threshold Alert l h Rire displays when Health Mode output 2 is inactive because of contamination The system operates normally but is nearing the alarm state e Threshold Error lear d Err displays when discrete output 1 is forced to the blocked state and can no longer be used to detect small objects The sensor may enter Health Mode Alarm for any of these reasons 1 When first powered up the fiber optic array may already be contaminated 2 Ifthe Window SET procedure fails indicating the fiber optic array is contaminated and the sensor could not set a valid clear state light level for reliable detection 3 Ifthe fiber optic array is contaminated enough that the auto compensation tracking algorithm cannot sufficiently adjust the thresholds to ensure reliable detection 4 Ifthe fiber optic array is blocked for more than 2 seconds Return the system to normal operation by cleaning the fiber optic array and performing a Window SET to reset the clear state light level see Window SET on page 6 12 www bannerengineering com Tel 1 763 544 3164 P N 178061 Rev C DF G2 High Speed Expert Dual Display Small Object Counter Specifications Sensing Beam Output Response Time Visible red 635 nm 25 us Supply Voltage 50 us 10 to 30 V dc Class 2 10 max ripple seh Hs s Power and Current Consumption exclusive of load 500 i Standard display mode 960 mW Current consumption lt 40 mA at 24 ae Vdc Repeatability ECO display mod
11. gnal Figure 3 Window SET Light Operate shown Output ON and OFF conditions can be reversed using the LO DO switch see LO DO Switch in Top Panel Interface on page 4 Window SET Follow these steps to perform a Window SET i Note TEACH Selection must be programmed to wind SEt see Program Mode on page 5 1 Enter Adjust Mode 6 www bannerengineering com Tel 1 763 544 3164 P N 178061 Rev C DF G2 High Speed Expert Dual Display Small Object Counter Method Action SET Button 4 Set Mode switch to ADJ Result Display Red Signal Level Green Threshold Remote Input 5 No action required sensor is ready for Window SET method 2 SET Sensing Condition Method Action Result e Present sensing condition e Click the SET rocker button SET Button Threshold Condition Accepted e Present sensing condition Displays read wind SEt then Singl Ise th tei t alternate PASS with Offset Remote Input Ingle pulse the remote npu Sensor returns to Adjust mode Threshold Condition Not Accepted Displays read wI nd SEt then alternate FAIL with minimum Offset for sensing condition Sensor returns to Adjust mode 3 Return to RUN Mode SET Button Move Mode switch to Run Display Red Signal Level Green Window Center see Figure 4 on page Remote Input No action required sensor returns to 7 for instructions on how to display Run mode automatically upper and lower thresholds Wi
12. nce of the taught conditions does not meet the required minimum 100 to 300 The difference of the taught conditions just meets exceeds the required minimum minor sensing variables may affect sensing reliability 300 to 600 The difference of the taught conditions sufficiently exceeds the required minimum minor sensing variables will not affect sensing reliability 600 The difference of the taught conditions greatly exceeds the required minimum very stable operation The Window and Light SET methods will flash a offset on the displays after a PASS or FAIL SET Result Offset Meaning PASS with Offset Displays the offset used for the SET method FAIL with Offset Displays the minimum required offset necessary to PASS the SET method FAIL without Offset Presented condition cannot be used for the SET method The Health Mode Alarm alerts you when preventative maintenance becomes necessary to ensure reliable sensing The Health Mode output 2 is Active when the system is OK and operating normally Health Mode output 2 becomes Inactive when the system is in a marginal state because of contamination The system still operates normally and can detect small objects but is nearing the alarm state When the system is completely contaminated and unable to ensure reliable sensing the system goes into the alarm state In the alarm state the discrete output 1 is forced to the blocked state and can no longer be used to detect small obj
13. ndow SET during RUN mode Upon sensor power up Window Center is displayed thr N S 4 S Vv Vv 1234 2200 1234 2000 1234 1800 A A A Upper Window Lower Threshold Center Threshold Displayed Displayed Displayed Figure 4 Upper and Lower Thresholds 4 SET Button 0 04 seconds lt Click lt 0 8 seconds Remote Input 0 04 seconds lt T lt 0 8 seconds See Troubleshooting on page 12 for more explanation of the Offset displayed after the Window SET method P N 178061 Rev C www bannerengineering com Tel 1 763 544 3164 DF G2 High Speed Expert Dual Display Small Object Counter e Sets a threshold a programmable offset below the presented condition e Changes output state on any condition darker than the threshold condition e Recommended for applications where only one condition is known for example a stable light background with varying darker targets e See Program Mode on page 5 for programming the Offset Percent setting A single sensing condition is presented and the sensor positions a threshold a programmable offset below the presented condition When a condition darker than the threshold is sensed the output either turns ON or OFF depending on the LO DO setting see LO DO Switch in Top Panel Interface on page 4 Threshold Position Sensor positions threshold a programmable offset below the presented condition Output ON Darkest Condition Most Light no signal Presented saturated
14. ngle pulse remote input 3 Present ON and OFF Conditions Method Action Result SET Button Present ON and OFF conditions Display Red Signal Level Green Threshold Remote Input Present ON and OFF conditions 4 Exit Dynamic TEACH 10 SET Button 0 04 seconds lt Click lt 0 8 seconds Remote Input 0 04 seconds lt T lt 0 8 seconds 10 www bannerengineering com Tel 1 763 544 3164 P N 178061 Rev C DF G2 High Speed Expert Dual Display Small Object Counter Method Action Result Displays alternate PASS with Minimum Differencel2 Sensor returns to Adjust mode SET Button Click the SET rocker button C TEACH Accepted T Remote Input Single pulse remote input TEACH Not Accepted Displays alternate FAIL with Minimum Differencel2 Sensor returns to Adjust mode 5 Return to RUN Mode Method Action Result RUN PRG ADJ SET Button Move Mode switch to RUN Display Red Signal Level Green Threshold Remote Input No action required sensor returns to RUN mode automatically 12 See Troubleshooting on page 12 for more explanation of the Minimum Difference displayed after the Dynamic TEACH method P N 178061 Rev C www bannerengineering com Tel 1 763 544 3164 11 DF G2 High Speed Expert Dual Display Small Object Counter The Dynamic TEACH method will flash a minimum difference on the displays after a PASS or FAIL PASS FAIL Description 0 to 99 The differe
15. or requires a mating cordset e For 9 m cable change the suffix 2M to 9M in the 2 m model number example DF G2 NC 9M e For 150 mm 6 in PVC pigtail M8 Pico QD connector 6 pin change the suffix 2M to Q3 in the 2 m model number example DF G2 NC Q3 Original Document 8 April 2015 178061 Rev C 178061 DF G2 High Speed Expert Dual Display Small Object Counter Fiber Optic Arrays Detection Window 2 Models Dimensions Fiber Exit Minimum Object Size 3 PFCVA 10X25 S Side exit 10 mm x 25 mm PFCVA 10X25 E End exit PFCVA 25X25 S Side exit 25mm x 25mm PFCVA 25X25 E End exit PFCVA 34X25 S Side exit 34mm x 25 mm PFCVA 34X25 E End exit Installation Instructions Mounting Instructions Mount on a DIN Rail 1 Hook the DIN rail clip on the bottom of the DF G2 over the edge of the DIN rail 1 2 Push the DF G2 up on the DIN rail 1 3 Pivot the DF G2 onto the DIN rail pressing until it snaps into place 2 Mount to the Accessory Bracket 1 Position the DF G2 in the SA DIN BRACKET 2 Insert the supplied M3 screws 3 Tighten the screws Remove from a DIN rail 1 Push the DF G2 up on the DIN rail 1 2 Pivot the DF G2 away from the DIN rail and remove it 2 2 Custom fiber arrays and mounting configurations are possible Consult factory for assistance with your small object counting application With 2 threshold offset percentage 2 www bannerengineering com Tel 1 763 544 3164 P N 178
16. osition All three button positions are used during PRG mode to navigate the display driven programming menu During ADJ mode SET is used to perform TEACH SET methods The rocker button is disabled during RUN mode except when using Window SET see Window SET on page 6 Red Green Digital Displays During RUN and ADJ mode the Red display shows the signal level and the Green display shows the threshold or the total counts During PRG mode both displays are used to navigate the display driven programming menu Output LED The output LED provides a visible indication when the output is activated www bannerengineering com Tel 1 763 544 3164 P N 178061 Rev C DF G2 High Speed Expert Dual Display Small Object Counter Operating Instructions Remote Input For more information about how to perform TEACH SET methods and to program the sensor remotely see www bannerengineering com and search 178236 Run Mode Run mode allows the sensor to operate normally and prevents unintentional programming changes The SET rocker button is disabled during RUN mode except when using Window SET see Window SET on page 6 In RUN Mode the SET function of the SET rocker button allows the user to toggle between the threshold center value and the total number of counts on the Green display If the Totalizer function is enabled the total counts value increments to the programmed value and then starts over at 0 If the Totalizer function is disa
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