- Platt Electric Supply
Contents
1. page 3 1 1 System Features 4 1 2 System COmDODeTIS De eic d ri 2 Specifications page 9 2 1 Emitter and Receiver Specifications 9 2 2 Emitter and Receiver Dimensions 10 2 3 Controller 5 lt 11 2 4 Controller Dimensions 12 3 Installation and Mechanical Alignment page 13 3 1 Emitter and Receiver 13 3 2 Controller 14 3 3 Emitter and Receiver 14 3 4 Controller Wiring and Output 15 Do VoM E IP eai a aii 18 1 1 9 0 3 0 9000 9 00 0 0 hoe 18 3 7 eal COMMMUNICIUON de ween ae Aen 16 4 Software Installation page 19 5 Controller 60 0 8 0 page 20 5 1 Gommunications Setup aca aoe aac oa CR OR e 20 5 2 Alignment 515 20 5 9 111111 cana cipi actae oer Ae ene d2. The Banner A GAGE MINI ARRAY measuring light screen is ideal for applications such as on the fly product sizing and profiling edge guiding and center guiding loop tensioning control hole detection parts counting die ejection verification and similar 565 A typical MINI ARRAY System consists of five components e a Controller module e an emitter and corresponding receiver and e two interconnecting cables sensors are available in array lengths from 6 to 4 in 6 increments plus 5 and 6 array models as listed on page 7 Sensors are available with either 9 5 mm 3 8 or 19 1 mm 3 4 beam spacing which translates to either 32 or 16 beams per foot of array length Sensors with 3 8 beam spacing have a sensing range of up to 6 m 20 sensors with 3 4 beam spacing have a sensing range of up to 17 m 55 5 and 6 arrays have shorter range see Specifications Paint Booth Profiling Inspection Applications Figure 1 1 Typical MINI ARRAY Applications Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 3 MINI ARRAY Instruction Manual System Overview 1 1 System Features Built in features simplify the operation of the A GAGE MINI ARRAY system Programmable beam blanking accommodates machine components or other fixtures that must remain in or move through the light screen Blanking is set by us
3. BANNER more sensors more solutions A GAGE MINI ARRAY Measuring Light Screen System MAC Series Controllers Instruction Manual Features Controller Models MAC 1 MACN 1 MACP 1 MACV 1 MACI 1 MAC16N 1 MAC16P 1 See Section 1 1 for additional model specific features applications in 6 increments plus 5 and 6 models Measuring Light Screen system for inspection and profiling Modular system with compact controller and a variety of BMEL BMRL series MINI ARRAY emitters and receivers sensors available with either 9 5 mm 3 8 or 19 1 3 4 beam spacing and with array lengths from 6 to 4 Controller is programmable for any one or two of ten measurement modes depending on model and any one of four scanning modes using a computer running Windows XP Vista or 7 and the Banner supplied software software is also supplied for display of error analysis via controller self diagnostics and for sensor alignment system status including alignment is displayed via LED indicators on the controller and on the receivers Controller may be programmed for blanking to ignore activity in one or two fields along the length of the array e Programmable hysteresis at the high and or low limit of each measurement area provides smoothing of output response also programmable for number of consecutive scans before an output update e Separate gate input e g from a presence sensor allows control of
4. Emitter or receiver problems may be further diagnosed using the diagnostics routine which is included with the MINI ARRAY software Launch the program by selecting Diagnostics under the MINI ARRAY menu see Figure 6 3 or press the F2 key The Diagnostics screen Figure 6 4 displays the type of each emitter and receiver module Board and its functional status State If an error has occurred the specific problem beam Channel will be identified Additionally If there is a problem with an emitter or receiver cable connection a No Response message will be displayed The Diagnostics routine also displays the part number and date code of the controller which may be useful information if factory assisted troubleshooting by telephone is required Mini Array Diagnostics Alignment Edit PSF Set Part Number Exit Figure 6 3 MINI ARRAY software Main Menu Diagnostics System State Operational Humber Of Emitter Boards 2 Number Of Reciever Boards 2 Board Num Channels Type State 118 0 No Errors 0 No Errors 0 No Errors 0 No Errors Part Number 000000 Date Code Figure 6 4 MINI ARRAY software Diagnostics screen Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 31 MINI ARRAY Instruction Manual System Operation Banner Engineering Corp Minneapolis MN U S A 38 www bann
5. Output 2 Disabled Discrete Outputs Set Point Hysteresis Analysis Mode L High Low High Scan Invert Y N Output 2 Disabled oe w ME Output 2 Other Features File Save PSF Upload PSF lt Alam Trigger Null Span File PSF exit Figure 5 9 Output assignments portion of PSF Configuration screen Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 25 Controller Configuration 26 MINI ARRAY Instruction Manual Hysteresis Low and High determines how much change must occur at each set point to cause the associated output to change state Hysteresis avoids unstable output conditions e g chattering of the output when the scanning condition exactly matches one of the set points The default setting for hysteresis is one beam less than the Low Set Point and one beam more than the High Set Point Scan is the number of consecutive scans of the array required before the associated output is updated The controller can be programmed for from one to nine consecutive scans The scan data MUST BE THE SAME for all consecutive scans for the outputs to be updated Invert Y N allows the output to be normally open No or normally closed Yes Models MAC16P 1 MAC16N 1 Discrete Outputs The sixteen discrete outputs are programmed using the Outputs button on the Multiple Output MINI ARRAY PSF Configurat
6. 30V dc ON STATE Saturation Voltage lt 1 Volt 10 mA lt 1 5 Volt 150 mA MACN 1 2 Open collector NPN transistor outputs MACP 1 2 Open collector PNP transistor outputs Transistor rated 30V max 150 mA max short circuit protected may be configured as a second data analysis output system alarm output or scan trigger output for a parallel array OFF STATE Leakage Current lt 10uA 30V ON STATE Saturation Voltage lt 1 Volt 10 mA lt 1 5 Volt 150 mA MACV 1 MACI 1 Alarm Open collector NPN transistor rated 30V dc max 150 mA max short circuit protected may be configured as a data analysis output system alarm output or scan trigger output for a parallel array OFF STATE Leakage Current lt 10 30V dc ON STATE Saturation Voltage lt 1 Volt 10 mA lt 1 5Volt 150 mA MAC16P 1 Sixteen open collector PNP transistor outputs MAC16N 1 Sixteen open collector NPN transistor outputs 30V max 150 mA max short circuit protected OFF STATE leakage current 10 ON STATE Saturation Voltage lt 1 Volt 10 mA lt 1 9V 150 mA MACV 1 2 0 10 Volts sourcing adjustable Null and Span 20 mA current limit MACI 1 2 4 20 mA current sinking adjustable Null and Span 16 to 30V input Resolution Span minus Null divided by the number of sensor channels Linearity 0 196 of Full Scale Temp Var 0 01 of Full Scale C All Models RS 232 ASCII or binary data format Baud rate 9600 19 2K or 38
7. program select Alignment under the MINI ARRAY menu see Figure 5 2 or Figure 5 2 MINI ARRAY software Main press the F3 key menu Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 20 P N 43298 rev E MINI ARRAY Instruction Manual Channel Broken Made Total 18 4 1 1 32 Alignment Controller Configuration 9 9 Alignment The Alignment screen Figures 5 3 and 5 4 identifies the location of the first and last beams made clear and broken blocked plus the total number of beams made and broken The beams are numbered in sequence from the cable end of the sensors to the top end This is valuable during setup for analyzing exactly what is being seen by the light screen The Diagnostics screen indicates any problems with the emitter or the receiver see Section 6 3 for more information Models MAC 1 MACP 1 MACN 1 MACV 1 and MACI 1 To display current information select the desired Channel Status Option Broken Made or Both and select Run The chart on the right side of the screen shows the status broken or made of each beam in the array Beam status is continuously updated to allow accurate positioning of the array and or analysis of sensing response To exit the Alignment screen first select Stop then select Exit Models MAC16P 1 and MAC16N 1 The Alignment screen Figure 5 4 displays the status of each beam along the entire length of the lig
8. 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 Lineman E i ese ied hracr ral Cm Beg eee epee ela Lux dp du Id ET I umm 298 Bims CEPI Lnag neo gps din sn py all niat eda 51 28 8 p gus Co and ah ane proc ss komd ip jn i panard ii Hor ims cad m 8 adit Mud 125 2 wid pedet hes od aane oni 6 8 a 191 gelled eee A iE LLL qund ain Pun LT eman gered mac ema uos 4 ri 1 pe ia fete aH Pii ee Deen i 72 Tren Pega m bhiir das peo 2 gt lcm T mihi pida c oak Rm adim Um iria andi n Firmini P rune x end yaj
9. ARRAY PSF Configuration Serial Communication Controller ID Baud Rate Control Mode Selection Serial Transmission Setup No Serial Communication Measurement Mode Result C All Mode Transmission Type Scanning Method Analysis Mode Selection Meas 1 Meas 2 None Serial Options Cancel Upload PSF Execute Outputs File Save PSF File Retrieve PSF Figure 5 6 MINI ARRAY software PSF Configuration models MAC16N 1 and MAC16P 1 22 43298 rev E MINI ARRAY Instruction Manual Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual Controller Configuration Many options yet easy to program The software included with the control module makes it easy to configure the MINI ARRAY using your PC compatible computer Simply load the software access the program and access the Edit PSF Configuration screen shown below Each option is easily selectable using your mouse and the pop up menu styles selections Running Windows 95 98 NT ME XP or 2000 Analysis Measurement Mode Selection Choose the measurement option that best tells you the size and or position of objects as they relate to the array Analysis Mode Selection Meas Scanning Method Straight scan polls each beam sequentially to determine the target object s overall s
10. Controller Wiring and Output Hookups Cable clearance dimensions for the arrays are shown in Figure 3 3 Controller connections are made via the wiring terminals along the front surface of each module Emitter and receiver hookups and controller outputs are shown in Figures 3 5 through 3 11 3 4 1 Model MAC 1 Controller Hookup Output 1 Controller terminals 9 and 10 OUT1 are reed relay contacts rated at 125V ac dc max 10 VA max resistive i e non inductive load It may be programmed as either normally open or normally closed Alarm Controller terminal 15 Alarm is an open collector NPN transistor switch rated at 30V dc max 150 mA max It is protected against overload and short circuits rH 500 mA V V 85485 10 30Vdc ins 150 mA Gate EMITTER and RECEIVER CABLES ALARM DRAIN BARE Figure 3 5 Model MAC 1 hookup 3 4 2 Model MACP 1 Controller Hookup Output 1 Controller terminal 9 OUT1 is an open collector PNP transistor switch rated at 30V dc max 150 mA max It is protected against overload and short circuits Alarm Controller terminal 15 ALARM is an open collector PNP transistor switch rated at 30V dc max 150 mA max It is protected against overload and short circuits Both outputs are current sourcing LLI lt m V V8 30V RS485 10 30Vdc Com 30V d 16 30V dc 150 mA Gate 150 mA EMITTER and 1 2 A Max Max Max RE
11. V 16 30V dc RECEIVER CABLES 16 Solid state Ouputs V 15 through 150 mA Max each Figure 3 10 Model MAC16P 1 hookup Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 17 MINI ARRAY Instruction Manual Installation and Alignment 3 4 7 Model MAC16N 1 Controller Hookup Terminals 15 through 30 are open collector NPN transistor outputs rated at 30V dc max 150 mA max They are protected against overload and short circuits All outputs are current sinking Controller terminal 15 output 16 may be used as an output or as an alarm Whenever this output is active the red Alarm LED is ON Lu lt V Ve n 16 30V dc Gate RECEIVER CABLES 16 Solid state Ouputs 15 through 150 mA Max each Figure 3 11 Model MAC16N 1 hookup 3 0 System Power Connect a 16 to 30V dc source to controller terminals 1 V and 2 V Connect a good earth ground to terminal 3 A good earth ground is important for providing electrical and RF noise immunity to the MINI ARRAY System The dc power source must supply 1 25 amps worst case when using the longest 6 sensors See Specifications Section 2 for more information 3 6 Gate DB 9 Pin Connect a switched 10 to 30V dc source as a gating input if required between paring controller terminal 11 and 12 Voltage is typically switc
12. and instructs the controller to resume normal operation Clicking the Cancel button disregards any Null Span adjustments and causes the controller to resume normal operation with the the previously saved null and span settings The MAC controller has a four minute Null Span time out feature that causes the controller to leave the Null Span adjustment procedure when neither the Null Update nor the Span Update functions are accessed When this time out condition occurs the MAC controller automatically cancels the Null Span adjustment procedure and returns to the previously saved settings Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 27 Controller Configuration 28 9 5 3 Analysis Mode Selection The MINI ARRAY controller is a versatile microcontroller based module that may be configured using a PC compatible computer running Windows XP Vista or 7 and the Banner supplied software via the built in RS 232 or RS 485 interface The Banner MINI ARRAY System can be programmed for any one or two of the following scan Analysis Modes see Figure 5 13 for examples All Data ALL The controller passes all beam condition data for every scan to the Serial interface for analysis by a host computer or controller First Beam Blocked FBB The controller identifies the location of the first beam blocked Beams are numbered beginning with the cabled end of the sensor and con
13. ba be Chr eet eer ieri chen dhii dn im ini 1 misi ry wur T 1 8 T De dm gem i nom piia PP Lors mares lai im d sup mm bo arem lo err 58708 d Figure 4 1 MINI ARRAY software installation dialog boxes Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 19 MINI ARRAY Instruction Manual Controller Configuration 5 Controller Configuration Configuration of the MINI ARRAY controller is accomplished with a Windows menu Style procedure using the Banner supplied software and a PC compatible computer running Windows XP Vista or 7 A serial data connection is made between the computer and the DB9 connector on the controller see Figure 3 12 Parameter Setup Files PSF are programmed configurations that can be stored in the control module s non volatile memory The Banner software can store various PSFs in computer files for instant call up of a particular configuration The Banner software also provides two additional features An Alignment screen and a Diagnostics screen 9 1 Communications Setup The MINI ARRAY software permits serial communication via RS 232 between the MAC controller and the PC The minimum connections to the DB 9 connector on the MINI ARRAY Controllers are a
14. during each scan For example with one beam skipped only beams 71 3 5 7 etc will be interrogated With two beams skipped only 71 4 7 10 etc will be interrogated and so on Receiver Interlaced Scan improves optical resolution in the middle one third of the scanning range Figure 5 17 Interlaced Scan Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 31 Controller Configuration 5 5 6 Control Mode Selection The controller can be programmed for Continuous scanning Gated scanning or for Host mode The module offers an optically isolated Gate input which is energized by application of 10 to 30V dc Gating is typically accomplished using a presence sensing device Host mode allows the array to be gated by a host computer or programmable logic controller PLC Host Control All MINI ARRAY Systems can communicate with a host computer or controller via RS 232 serial protocol In addition controller models MAC 1 MACN 1 and MACP 1 also can communicate via RS 485 The host can direct the MINI ARRAY System to scan on demand and or receive the scan data directly from the MINI ARRAY System in binary or ASCII form Selectable communication baud rates are 9600 19200 and 38400 5 6 Serial Communication The MINI ARRAY System can communicate with its host computer or controller via either RS 232 all models or RS 485 MAC 1 MACN 1 MACP 1 serial
15. m s Red Blocked LED Green Align LED Yellow Marginal Alignment LED RS 232 Port Figure 1 2 A GAGE MINI ARRAY System features Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 4 P N43298 rev E MINI ARRAY Instruction Manual System Overview 1 1 1 Model Specific Features Models MAC 1 MACN 1 and MACP 1 e Supports serial communication with a host computer or PLC via RS 232 or RS 485 interface enables a computer or PLC to process scan data and or initiate scans serial data may be either ASCII or binary e Up to 15 controllers may be assigned separate IDs and placed on RS 485 party line e MAC 1 Two outputs one reed relay and one NPN transistor output either output may be inverted i e programmed for normally open or normally closed MACN 1 and MACP 1 Two discrete open collector PNP current sourcing or NPN current sinking transistor outputs depending on model Models MACV 1 and MACI 1 e Analog output null and span can be adjusted via PC interface and supplied software e Analog output signal can have either a rising or falling slope e Analog outputs will automatically adjust to sensor length e Discrete output is an open collector NPN current sinking that can be used as an alarm a trigger or used with an Analysis Mode Selection output capable of being inverted in Analysis Mode e MACV 1 Two linear sourcing analog voltage outputs 0 to 10 v
16. protocol The host can direct the MINI ARRAY to scan on demand and or receive the scan data directly from the MINI ARRAY System in Binary or ASCII form Selectable communication baud rates are 9600 12000 and 38400 Figure 5 19 Protocol is One start bit one stop bit 8 data bits and even parity See the Appendix for more information on data formats When RS 485 communication is used each controller module may be assigned a controller ID Select letter A through O for individual identification of up to 15 Controllers on a RS 485 party line 5 6 1 Serial Transmission Serial Transmission activates the serial port specifies the data format and provides data suppression options If No Serial Communication is selected default the serial port does not transmit sensing data See Figure 5 20 ASCII Transmission specifies that the scan data will use the ASCII format ASCII Transmission has one suppression option called Suppress Clear Data which means that data is sent one time when the array is completely clear i e when no beams are blocked and no further data is sent until one or more beams are blocked Binary Transmission specifies that the scan data will use the binary format The binary format has three suppression options The first option is Suppress Clear Data which means that data is sent once when the array is completely clear i e when no beams are blocked and no further data is sent until one or more beams are blocked T
17. to 7 milliseconds processing time Polycarbonate NEMA 1 IP20 Temperature 20 to 70 4 to 158 F Maximum Relative Humidity 95 non condensing 2 4 Controller Dimensions BBRBBeBgggegggu Jaa 110 0 mm 4 33 100 0 mm 75 0 3 94 2 95 85 3 mm 3 36 Combo Head Phillips Slotted Screws M3 5 x 0 6 mm x 14 mm 2 6 x 0 5 equivalent supplied 35 0 mm M3 5 Washers 2 6 equivalent supplied 1 38 M3 5 mm x 0 6 mm Nuts 2 6 equivalent supplied Din mounting slot Recommended torque is 16 20 in Ibs on mounting screws Slot for screws 2 M3 5 x 0 6 mm 2 Din mounting tab 2 supplied Figure 2 2 Control module dimensions and mounting hole locations Banner Engineering Corp Minneapolis MN U S A 12 P N 43298 rev E www bannerengineering com Tel 763 544 3164 _MINVARRAY nstallatign and Mechanical Alignment Instruction Manual 3 Installation and Mechanical Alignment 3 1 Emitter and Receiver Mounting Banner MINI ARRAY emitters and receivers are small lightweight and easy to mount the mounting brackets supplied allow 30 degrees rotation From a common point of reference make measurements to position the emitter and receiver in the same plane with their midpoints directly opposite each other Mount the emitter and receiver brackets using the MA x x 14 mm bolts and associated mounting hardware all supplied See Figure 3 1 Alth
18. 1810 mm 71 25 BMEL632A BMRL632A 143 mm 5 62 6 Quick Disconnect BMEL1232A BMRL1232A 295 11 62 32 Cables BMEL1832A BMRL1832A 448 mm 17 62 Figure 1 3 MINI ARRAY system components BMEL2432A BMRL2432A 600 mm 23 62 _BMEL2432A BMRL2432A 1 2 2 Controller to Sensor Cables BMEL3032A BMRL3032A 752 29 62 EM required per system BMEL3632A BMRL3632A 905 mm 35 62 7 6 m 25 15 2 50 BMEL4232A BMRL4232A 1057 mm 41 62 ER m BMEL4832A BMRL4832A 1210 mm 47 62 BMEL6032A BMRL6032A 1514 mm 59 62 MAQDC 575C 22 7 m 75 MAQDC 5100C 30 3 m 100 BMEL7232A BMRL7232A 1819 71 62 37 9 m 125 MAQDC 5150C 45 5 m 150 Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 1 MINI ARRAY Instruction Manual System Overview 1 2 3 MINI ARRAY MAC Series Controller Models Discrete Reed Relay Discrete NPN Discrete NPN Discrete PNP Discrete PNP 1 Sensor Pair 2 Analog 1 Gate 0 to 10V dc Sourcing Discrete NPN 2 Analog 4 to 20 mA Sinking RS 232 16 Discrete NPN Outputs 59114 16 Discrete PNP Outputs Dimensions for all MAC Series Controllers listed above are 110 x 100 x 75 mm 4 3 x 3 9 x 3 0 see Figure 2 2 See Section 5 5 3 for a detailed description of available scan analysis modes Banner Engineering Corp Mi
19. 1910 0 mm 75 2 MINI ARRAYS Instruction Manual With mounting bracket flanges in 30 1 mm Square 1 50 177 0 mm 6 97 332 8 mm 13 1 481 8 mm 18 97 636 3 mm 25 05 786 6 mm 30 97 940 5 mm 37 0 1091 0 mm 43 0 1244 0 mm 49 0 1549 0 mm 61 0 1853 0 mm 73 0 Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual Specifications 2 3 Controller Specifications 16 to 30V dc 1 25 amps max see current requirements for sensors Controller alone without sensors connected requires 0 1 amp MINI ARRAY sensor input 5 connections emitter and receiver wire in parallel to five terminals GATE input Optically isolated requires 10 to 30V dc 7 5K input impedance for gate signal Outputs are not active for 5 seconds after system power up Maximum response time for the discrete outputs is two scan cycles A scan cycle includes a sensor scan plus any serial data transmission Serial transmission if activated follows every sensor scan MAC 1 Output 1 OUT 1 Reed relay contact rated 125V ac dc max 10 VA max resistive load non inductive Output 2 ALARM Open collector NPN transistor rated 30V dc max 150 mA max short circuit protected may be configured as a second data analysis output system alarm output or scan trigger output for a parallel array OFF STATE Leakage Current lt 10
20. 4K 8 data bits 1 start bit 1 stop bit even parity Clear data may be suppressed header string may be suppressed in binary format MAC 1 MACN 1 and MACP 1 Up to 15 Controllers may be given unique address for RS 485 party line Via RS 232 to PC compatible computer running Windows XP Vista or 7 operating system and using Banner supplied software see user manual Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 11 MINI ARRAY Instruction Manual Specifications 2 3 Controller Specifications continued The following status LEDs are located on the front panel OUTPUT 1 red name and function vary depending on model Indicates active output ALARM red Indicates that Output 2 or 16 is active depending on model GATE red Indicates voltage is applied to GATE input ALIGN green Indicates sensor aligned excess gain gt 1x Plus three diagnostic LEDs DIAG1 green Indicates power is applied to the module DIAG2 red Indicates receiver failure DIAG3 red Indicates emitter failure For all models 55 microseconds per beam plus processing time The processing time is dependent on the scan analysis and the number of active outputs This timing assumes a Straight scan continuous and TBB mode MAC 1 MACN 1 amp MACP 1 1 millisecond processing time MACV 1 amp MACI 1 1 5 milliseconds processing time MAC16N 1 amp MAC16P 1 2 3
21. CEIVER CABLES ALARM Out Figure 3 6 Model MACP 1 hookup Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 15 MINI ARRAY Instruction Manual Installation and Mechanical Alignment 3 4 3 Model MACN 1 Controller Hookup Output 1 Controller terminal 9 OUT1 is an open collector NPN transistor switch rated at 30V dc max 150 mA max It is protected against overload and short circuits Alarm Controller terminal 15 ALARM is an open collector NPN transistor switch rated at 30V dc max 150 mA max It is protected against overload and short circuits Both outputs are current sinking V Ve 30V RS485 10 30V de Com Out1 16 30V de Max 150 mA RECEIVER CABLES ALARM Max DRAIN BARE Figure 3 7 Model MACN 1 hookup 3 4 4 Model MACV 1 Controller Hookup Voltage outputs 1 and 2 Controller terminals 9 V out 1 and 13 V out 2 are analog voltage outputs The load for analog voltage Output 1 should be tied across terminals 9 and 10 The load for analog voltage Output 2 should be tied across terminals 13 and 14 Both switches are rated at 10V dc max 10 mA max Both outputs are voltage sourcing Alarm Controller terminal 15 ALARM is an open collector NPN transistor rated at 30V max 150 mA max current sinking V V 16 30V de EMITTER and 1 2 A Max RECEIVER CABLES Lu lt Figure 3 8 Mod
22. able lengths Cables measure 8 1 mm 0 32 dia and are shielded and PVC jacketed conductors are 20 gauge e Use only Banner cables which incorporate a twisted pair for noise immunity on RS 485 data communication lines e Emitter and receiver cables may not exceed 250 each Emitter Receiver Red LED lights for proper operation Green sensors aligned 3x excess gain Yellow marginal alignment 1x 3x excess gain Red sensors misaligned or beam s blocked NEMA 4 13 IEC IP65 Aluminum housing with black anodized finish acrylic lens cover Temperature 0 to 70 C 4 to 158 F Max rel humidity 95 non condensing Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 9 Specifications 10 2 2 Emitter and Receiver Dimensions With mounting bracket flanges out Optical Channel 9 5 mm 3 8 Beam Spacing 19 1 mm 3 4 Beam Spacing 38 1 mm 1 50 505 0 mm 19 9 659 0 26 0 810 0 31 9 963 0 37 9 1115 0 43 9 1267 0 mm 49 9 1572 0 mm 618 9 1877 0 73 9 Figure 2 1 Emitter and receiver mounting dimensions and defined area location P N 43298 rev E 233 9 9 21 389 7 mm 15 357 538 7 mm 21 22 693 2 mm 27 31 843 5 33 23 997 4 mm 39 29 1148 0 mm 45 2 1301 0 mm 51 2 1606 0 mm 63 2
23. atures Quit Alarm Trigger Null Span File Retreive PSF Send PSF Figure 5 21 MINI ARRAY software Save PSF screen Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 33 Controller Configuration Instruction Manual Retrieving a PSF from Disk To retrieve a filed PSF select File Retrieve PSF The FileBox subscreen will appear Figure 5 22 Select the desired PSF from the File Name list and then select OK or press the Enter key The selected PSF will load to the PSF Configuration screen and can be loaded into the controller using the Send PSF command PSF Configuration Directories c minia inspect psf gt c profile1 psf 2 minia profile2 psf C dosexamp List Files of Type Drives 82 1 Discrete Outputs Set Point Hysteresis Analysis Mode Low High Low High S can 8 Invert Y N Output 2 Disabled 2 11 JEC 4 Output 2 Other Features Execute CO Alarm Nul Span File Retreive PSF Send PSF Figure 5 22 MINI ARRAY software Retrieve PSF screen PSF Output Analysis To view activity in the array in response to the currently loaded PSF select Execute The Measurement Output screen will appear Figure 5 23 Select Run The table will display the status for the selected measurement mode s including the Present value and the High and Low va
24. ay be assigned to Output 2 Programmable output response criteria are described in the following sections All models except the 16 output models have an output labeled Alarm This output can be programmed to function as the alarm output for the controller s self diagnostic circuitry whenever a scan analysis mode is not assigned to it The output may instead be programmed to serve as a trigger input to begin the scan sequence of another MINI ARRAY System Models MAC 1 MACP 1 MACN 1 MACV 1 and MACI 1 Discrete Outputs The Output Assignments portion of the PSF Configuration screen shown in Figure 5 9 allows complete customization of response of the selected Analysis Mode s With the exceptions noted either Meas1 or Meas2 can be assigned to Output 1 or Output 2 Output 2 may be assigned as an Alarm output for the module s self diagnostic circuitry whenever a scan analysis mode is not assigned to it Output 2 can also be programmed to serve as a Trigger input to begin the scan sequence of another MINI ARRAY System The Trigger value is the beam location along the array at which the Trigger output during a scan occurs Set Point Low and High determines where within the array the output s will respond In the case of total or contiguous beams made or broken these settings determine the minimum and maximum number of beams required for an output Analog Output Analysis Mode Scan Invert YZH Output H1 Disabled E Mo
25. ch are selected via the Edit PSF Screen of the supplied software Once the Analysis Mode Selection is specified for Meas1 and Meas2 the Analog Output can specified via the Analog Output choices The analysis mode is selected as Meas1 Meas2 or Disabled The Disabled option means the output is not utilized Meas1 and Meas2 reflect the choices provided with the Analysis Mode Selection The scan provides a means to average from 1 to 9 scans before the analog output gets updated The Invert option changes the output from a rising signal to a falling signal Null Span Adjustment The user can adjust both the zero and full scale reading for both analog outputs of MACV 1 and MACI 1 Controllers This adjustment is implemented via the Edit PSF screen Null Span button which activates the Null Span menu Figure 5 12 Null Span Analog 0 81 0 1000 2000 4095 Analog Output o WE TT em Span 2239 2000 4095 Null Update Span Update Figure 5 12 Null Span Menu The Null Span menu causes the controller to temporarily respond to scaling adjustments The Null and Span ranges can be adjusted as follows mava 301v mua asm 78m 22m Each output s Null and Span is independently adjusted via the separate sliding bars When the adjustments are made the new values can be temporarily monitored by selecting either the Null Update or Span Update button The OK button saves the new settings
26. closed Yes Scan 1 9 Analog outputs are updated with an average value of the data received during the selected number of scans discrete outputs respond only if the received data is identical for all of the selected number of consecutive scans Set Point and Hysteresis Selection Assigns the set point to determine where within the array the output s will respond and hysteresis values to smooth output response Alarm Trigger Assigns an analysis Output 2 may instead be programmed to serve Nau oae measurement mode as a trigger input for another MINI ARRAY or to each output ALARM for the self diagnostic circuitry Downloadable Software To test and verify software download MINI ARRAY version 1 3 43989 exe or Multiple 16 Output version 1 0 59114 10 exe at www bannerengineering com Figure 5 7 Use the PSF Configuration screen to program each control module individually see Figure 5 10 for 16 output models Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 23 MINI ARRAY Instruction Manual Controller Configuration Parameter Setup Files Available for Each Controller Model ALL All data passed to host FBB First Beam Blocked LBB Last Beam Blocked MAC16N 1 MAC16P 1 X 5 One or two fields may be r blanked Blanking conditions are unlimited 2 to 16 outputs depending on model Straight Scan Interlaced Scan Edg
27. coded by the two byte number 0x01 0x06 P N 43298 rev E Definitions for ASCII Data Values For the ALL measurement mode Character Ch 4 Ch3 Ch2 C F E D C B A 9 8 7 6 4 3 2 1 0 0 3 323 3 aS 5 5 SE Figure A 1 ASCII Data Values Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual Appendix Figure A 2 shows that the binary transmission has three independent options These options are independently selected and are used to custom configure the No Serial Communication serial data format The Suppress Clear Data option is applicable when the sensor io ASCII Transmission is unobstructed While the sensor is blocked serial data is transmitted once the Suppress Clear Data sensor is unobstructed the clear data is transmitted once and then no further data transmission occurs until the sensor is again blocked The Suppress Header option will serially transmit the array data bytes The three header bytes are not transmitted Geral Transmission Binary Transmission suppress Clear Data The Compress Data option affects the data bytes for the measureme
28. e MINI ARRAY controller then waits for the next command string Serial Data Format The programmed measurement mode or modes determine the type of information that is transmitted For example if Meas1 is set for FBB and 2 is set for LBB then the data transmitted to the host contains the values of the first and last beam blocked The ALL measurement mode provides the status of all beams to the host The VHS mode does not provide serial output data In addition to measurement mode information the data transmission also contains a Start string and a termination byte The start string consists of two unsigned character bytes Hex value 10 The controller ID value The termination byte is the ASCII character for a linefeed hex value 0A These three bytes are collectively called the Header Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 39 Appendix 40 ASCII Format Data Transmission There are two ASCII formats The one used depends upon which measurement modes are selected For the ALL measurement mode each data byte is presented in an eight bit ASCII format which conveys the status of four consecutive channels four consecutive beams Each subsequent byte conveys the status of the next four channels until the status of all channels is reported MINI ARRAY Instruction Manual The allowable data values are the ASCII numbers 0 to 9 and the ASCII l
29. e Scan Skip Scan Continuous scanning Gate Mode scanning controlled by applying 10 30V dc to GATE input Host Mode scanning controlled by host computer or PLC ne Defines baud rate and controller I D Activates serial data transmission and specifies data format X After a PSF is configured it may be sent to the controller The PSF may also be saved for call up at a later time Many PSFs may be saved within PC files for quick controller configuration whenever a setup change is required Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 24 P N 43298 rev E MINI ARRAY Instruction Manual Controller Configuration 9 9 Creating New Parameter Setup Files PSFs Analysis Mode Selection 5 5 1 Analysis Mode Assignment One or two Measurement Analysis modes may be programmed Meas1 or Meas2 may be assigned to one or both outputs Figure 5 8 If ALL is selected in either Analysis mode all of the scanning information is sent via the serial connection to a host computer or PLC The selection of ALL does not allow output assignments to be made to that measurement mode The available Analysis Modes are listed on page 24 and described on page 28 Figure 5 8 MINI ARRAY Software Analysis 9 9 2 Output Programming Mode Selecon The controller offers 2 3 or 16 outputs depending on the model One scan analysis mode may be assigned to Output 1 and a second different analysis mode m
30. el MACV 1 hookup Banner Engineering Corp Minneapolis MN U S A 16 P N 43298 rev E www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual Installation and Alignment 3 4 5 Model MACI 1 Controller Hookup Current outputs 1 and 2 Controller terminal 9 out 1 and 13 out 2 are analog current outputs The load for analog current Output 1 should be connected between an external 16 to 30V dc power supply and terminal 9 The load for analog current Output 2 should be connected between an external 16 to 30V dc power supply and terminal 13 The load external power supply return should be common with the controller power supply return Both outputs are current sinking Alarm Controller terminal 15 ALARM is an open collector NPN transistor rated at 30V dc max 150 mA max It is protected against overload and short circuits DRAIN BARE V Ve 30V 4 20 mA 16 30V dc 150 mA l out 2 EMITTER and 1 2 A Max RECEIVER CABLES Figure 3 9 Model MACI 1 hookup 3 4 6 Model MAC16P 1 Controller Hooku Terminals 15 through 30 are open collector PNP transistor outputs rated at 30V dc max 150 mA max They are protected against overload and short circuits The isolated gate input is at pins 11 and 12 Controller terminal 15 output 16 may be used as an output or as an alarm Whenever this output is active the red Alarm LED is ON All outputs are current sourcing DRAIN BARE V
31. erengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual Appendix Appendix Host Mode Command and Serial Data Format Host Mode Command The MINI ARRAY controller can communicate with a computer or PLC via either an RS 232 connection all models or RS 485 connection discrete output models See hookup information in Section 3 4 The host can respond to output from the controller when the controller is programmed for either the Continuous or Gate control mode see Section 5 5 6 Alternately the host can control sensor scanning When the Host control mode is Selected the host computer or controller initiates scans using a command string The command string is a three byte message consisting of Control byte with decimal value 248 Controller ID one of 16 ASCII letters A through O as specified in the PSF scan initiation byte ASCII letter S The command string is further defined as follows unsigned char msg 3 declare three byte unsigned character array using C language msg 0 248 control byte msg 1 65 the controller ID is the letter A msg 2 83 scan initiation byte which is the ASCII letter S The host transmits this three byte message at the defined baud rate The format is one Start bit one stop bit even parity and eight data bits When this message is received by the MINI ARRAY controller the controller initiates a scan and then updates its outputs as required Th
32. etters A to F In the table shown in Figure A 1 the represents a clear channel and the 1 represents a blocked channel The other measurement modes use three ASCII bytes to represent their values For example if Meas1 is FBB and Meas2 is LBB and the measured values are 6 and 120 and the controller ID is A then the data string is as follows 0xic 0 0 6 1 2 0 0x0a The controller allows suppression of clear data This means that data is sent one time when the array is completely clear i e when no beams are blocked and no further data is sent until one or more beams is blocked Binary Format Data Transmission There are two binary formats The one used depends upon which measurement modes are selected For the ALL measurement mode each data byte conveys the status of eight consecutive beams Each bit of the byte is directly related to the status of an individual channel As an example if the first eight beams are as follows Channel Status Binary Code 1 Blocked 1 2 Clear 0 3 Blocked 1 4 Blocked 1 Clear 0 6 Blocked 1 Clear 0 8 Clear 0 then the data byte has the hex value of 0x2d 45 decimal If the array has 32 optical channels then there would be 4 data bytes representing the status of all 32 optical channels The other measurement modes use two bytes to represent the measured value The first of the two bytes is the most significant As an example the value of 262 for the FBB measurement mode is
33. fective 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 INNO EVENT SHALL BANNER ENGINEERING CORP BE LIABLE 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 INCONTRACT 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 Banner Engineering 9714 Tenth Ave No Minneapolis MN USA 55441 Phone 763 544 3164 www bannerengineering com Email sensors bannerengineering com
34. he Suppress Header option reduces the size of the controller serial message by three bytes Header bytes consist of the two byte start string plus the termination byte The Compress Data option in many cases reduces the number of data bytes sent for each analysis mode from two to one byte See the Appendix for additional information Banner Engineering Corp Minneapolis MN U S A 32 P N 43298 rev E MINI ARRAYS Instruction Manual Control Mode Selection a Continuous bate Host Mode Figure 5 18 MINI ARRAY software control mode selection Senal Communication Baud Hate 9600 Controller ID Figure 5 19 MINI ARRAY software Serial Communication Parameter selection Geral Transmission Serial Communication C ASCII Transmission Suppress Clear Data C Binary Transmission Suppress Clear Data Suppress Header Compress Data Figure 5 20 Serial communication options www bannerengineering com Tel 763 544 3164 566666666666666 _MINARRAY______ Controller Configuration 9 7 PSF Assignment and Storage The screens shown in Figures 5 20 through 5 22 are for MAC 1 MACP 1 MACN 1 MACV 1 and MACI 1 Controllers The screen layouts for MAC16N 1 and MAC16P 1 are functionally the same and do not need to be shown separately PSF commands are located in the lower right corner of the PSF Configuration screen Sending a PSF to the Controller After a PSF is co
35. hed by the open 27 Transmit TX collector output transistor of a sensing device 3 7 Serial Communication EE RS 485 Models MAC 1 MACP 1 and MACN 1 only Connect RS 485 lines if used to terminals 13 and 14 Figure 3 12 DB9 serial connector R 232 Prepare an RS 232 cable using a DB 9 male connector with the connections shown in Figure 3 12 NOTE DO NOT use a null modem RS 232 cable Banner Engineering Corp Minneapolis MN U S A 18 P N 43298 rev E www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual Software Installation 4 Software Installation The Parameter Setup Software CD includes an installation program that quickly and easily loads the MINI ARRAY configuration program into the computer The 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 per the following Models MAC 1 MACI 1 MACN 1 MACP 1 MACV 1 CD P N 75877 Models MAC16N 1 MAC16P 1 CD P N 75878 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
36. ht screen The information displayed includes the total number of optical channels labeled as Beams the number of blocked made and blanked beams Each channel state is indicated as either 1 made 0 blocked or B blanked Other alignment functions allow the user to scan on a step command and to adjust the blanking fields Each channel can be individually blanked When a channel is blanked the controller ignores the state of the channel and does not consider the channel when calculating measurement mode data See Section 5 5 4 for more information about blanking Beams Total 64 Channel Status Options Broken Blocked 0 Hade 64 Blanked 0 Clear Blanking Fields 1 0 Blocked B Blanked Restore Controller Settings 865 tate tria Boo or ala 1 16 11113 1111 1111 1111 Auto Blanking n 1111 1111 1111 1111 Abon Aute Blank aur 1111 1111 1111 1111 Abort Auto Blanking 1111 1111 1111 1111 Save To File Made Head From File Cancel Made Use the Edit button to manually set blanking fields Figure 5 3 MINI ARRAY software Alignment screen models Figure 5 4 Alignment screen models MAC16P 1 and MAC 1 MACP 1 MACN 1 MACV 1 and MACI 1 MAC16N 1 Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 21 Controller Configuration 9 4 Parameter Setup Files PSFs The inp
37. ing options are changed using the supplied software Under the MINI ARRAY tasks select the Alignment function to access the Alignment screen Figure 5 4 The Start button causes the system to scan and update the Alignment screen Blanking commands include Clear Blanking Fields Restore Controller Settings Auto Blanking Abort Auto Blanking Save to File Read From File Cancel OK and Edit Clear Blanking Fields removes all blanking specifications Restore Controller Settings reads the previously saved blanking specifications from the MINI ARRAY controller Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 29 MINI ARRAY Instruction Manual Controller Configuration Auto Blanking selects all blocked channels for blanking When the Auto Blanking feature is selected the settings may be accepted or aborted Abort Auto Blanking cancels Auto Blanking File Save and File Retrieve allow the user to save and retrieve blanking data to a file The OK button saves the new blanking configuration to the controller After the OK button is selected Restore Controller Settings will reflect the new blanking configuration The Cancel button prevents the new blanking configuration from being saved The Edit function allows individual beams to be blanked Selecting the Edit function launches the Channel Blanking Edit Screen shown in Figure 5 15 Edit Channel Blank S
38. ing the included configuration software See Section 5 5 4 for more information Built in diagnostic programming and easy to see indicators on the sensors and the control module make alignment and troubleshooting easy Figure 1 2 The emitter has a red LED that signals proper operation The receiver has three bright LEDs green Signals that the sensors are properly aligned yellow signals marginal alignment and red signals misalignment or a blocked condition The control module has seven status indicators 5 red LEDs signal when outputs are conducting see Section 3 for more information Alarm output conducting and gate signal received a green LED signals that the sensors are properly aligned DIAG 1 2 and 3 LEDs indicate system status A key to the diagnostics codes is printed on the side of the control module for simplified troubleshooting see Section 6 3 The MINI ARRAY System provides a wide selection of sensing and output options including measurement scan analysis modes and scanning methods that can determine the target object s location overall size total height or total width Scanning may be continuous or controlled by a host process controller or a gate sensor Some models MAC1 MACP MACN support RS 485 where up to 15 systems may be networked Emitter Receiver DIN Rail Mountable Control Module Red Discrete Output 1 LED Red Alarm Discrete Output 2 LED gt 2 ib tional Green Alignment LED
39. ion screen Figure 5 10 The Outputs Button launches the Edit Discrete Outputs screen Figure 5 11 which allows the Set Points and Hysteresis levels to be defined for each output Set Point and Hysteresis values may be configured individually for each output and assigned to either 51 or Meas2 Set Point level defines the condition where the output is in the true condition For a typical application the output will be active when the Measurement mode result is between the set point limits If the inverted option is specified the output will be inactive when the Measurement mode result is between the set point limits i e the true condition The Hysteresis Low and High levels determine when the output will change back to the false condition The SEG measurement mode uses the Set Point Low and High levels to define segmentation of the light screen As an example Output 1 Set Point Low is 5 and the Set Point High is 20 These two values define beams 5 through 20 as a segment Whenever any of these beams are blocked this segment of the light screen is considered blocked and Output 1 will be active or inactive if Inverted is selected For the SEG measurement mode the Hysteresis specification is inactive The Scan Number may be used to change the number of consecutive scans necessary to change the output When the Scan Number is set to one the output will change after only one scan If the Scan Number is set to five the outpu
40. ize This is the most accurate and precise measurement but also the most time consuming Interlaced alternates a straight scan with a slanted beam scan to improve optical resolution in the center one third of the sensing range Edge activates only the beams located near the top edge of the Object in the light screen to reduce sensing response time Skip one to seven beams skipped reduces response time Minimum object detection size increases proportionally to the number of beams skipped Analog and Discrete Output Assignment Control Mode Selection Continuous Mode The control module constantly polls the array for status Gate Mode The control module polls the array for status when prompted by an input from a Gate sensor Host Mode The control module polls the array for status when prompted by a host controller Serial Communication Changes the identification and baud rate of the controller being configured Gate Meas2 None Host Mode __ Scanning Serial C RE 2 ice Baud Rate Edge Controller ID Os T g e Serial Transmission No Serial Communication ASCII Transmission Suppress Clear Data Binary Transmission Le Header Blanking Allows either 1 or 2 areas of the array to be blind to the activity of the area specified Serial Transmission Choose ASCII binary or no serial communication Invert Allows output to be normally open No or normally
41. lues for the Run period PSF Configuration Select Stop to freeze the data Select Step to initiate a single scan of the array This simulates a snapshot of what is viewed by the array when Step is selected Serial Transmission e No Serial Communication Use of the Execute command is especially beneficial for testing the ASCII Transmission response of a gated system Run oe Simulates the Continuous scanning Suppress Clear Data mode and Step simulates a gate input Analog Output Suppress Header command Analysis Mode Scant Invert Y N Compress Data Output 1 Disabled To close the PSF Configuration screen EUN LN select either Quit or Exit utput 2 Disabled 8 No Discrete Outputs Set Point Hysteresis Analysis Mode Low Output 2 Other Features File Save PSF Upload PSF Alarm Triger Nul Span File Heueive PSF Send PSF Figure 5 23 MINI ARRAY software PSF Output Analysis Low High Scan 8 Invert Y N Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 34 P N 43298 rev E MINI ARRAY Instruction Manual System Operation 6 System Operation 6 1 Sensor Operating Status Indicators NOTE Status indicators appear to freeze if the controller has been configured for the Gate or the Host Mode see Section 5 5 6 and there is no signal to cause a scan update Emitter Figu
42. nfigured by the selections made above the PSF is sent to the MINI ARRAY controller by selecting Send PSF This command loads the PSF into the controller s non volatile memory and automatically overwrites any existing PSF The program will confirm that the PSF was accepted or it will prompt for changes that are still required Retrieving a PSF from the Controller To check the PSF that is currently loaded into the controller select Upload PSF The current PSF will be displayed on the PSF Configuration screen Saving a PSF to Disk To place the displayed PSF into a file that can be retrieved at any time select File Save PSF When prompted whether to save the PSF to a file select Yes A subscreen titled FileSave will appear Figure 5 20 Overtype psf in the File Name entry box by entering the name of the file to be stored up to 8 characters plus the psf extension and then select OK or press the Enter key For example type the name Inspect1 psf and select OK The PSF is stored on the selected drive default is C and the program automatically returns to the PSF Configuration screen PSF Configuration t nTa nani Canker ariz AFATIT Risaking yan Fin shiny ee EEE File Name Directories inspect2 psf 2 minia dosexamp Discrete Outputs Set Point Hysteresis Analysis Mode Low High Low High S can 8 Invert Y 7M Output 1 Disabled ME Output 82 oo 847 E Output 2 Other Fe
43. nneapolis MN U S A www bannerengineering com Tel 763 544 3164 8 43298 rev E MINI ARRAY Instruction Manual Specifications 2 Specifications 2 1 Emitter and Receiver Specifications 9 5 mm 3 8 Beam Spacing 19 1 mm 3 4 Beam Spacing 0 6 to 6 1 m 2 to 20 for sensors lt 4 0 9 to 17 m 3 to 55 for sensors lt 4 0 6 to 4 6 m 2 to 15 for sensors gt 4 0 9 to 14 m 3 to 45 for sensors gt 4 NOTE Maximum range is specified at the NOTE Maximum range is specified at the point point where 3x excess gain remains where 3x excess gain remains 9 5 mm 3 8 Beam Spacing 19 1 mm 3 4 Beam Spacing 19 1 0 75 36 1 mm 1 5 Interlaced Mode 12 7 mm 0 5 Interlaced Mode 25 4 mm 1 0 NOTE Assumes sensing is in middle NOTE Assumes sensing is in middle one third of scanning range one third of scanning range 55 microseconds per beam plus 1 millisecond processing time per scan Assumes straight scan continuous scan and TBB mode see Section 5 5 5 Scanning Modes for further information Emitter Receiver 0 10 amps 12V dc 9 5 3 8 beams 0 75 amps Q 12V dc max NOTE Maximum current is for a 6 sensor 19 1 53 4 beams 0 50 amps 12V dc max NOTE Maximum current is for a 6 sensor Emitter and receiver connect to controller using two 5 conductor quick disconnect cables one each for emitter and receiver ordered separately See Section 1 for available c
44. nnel and the receiver s first channel and between the emitter s third channel and receiver s second channel continuing up the array to the last emitter channel and next to last receiver channel The last emitter channel is then reactivated to establish a beam to the last receiver channel to complete the scan Alternating this slanted beam scan with a straight scan improves optical resolution within the middle one third of the scanning range See Figure 5 17 Scanning Method Figure 5 16 MINI ARRAY software scanning method selection Edge Scan activates only the beams located near the top edge of an object in the light screen Top edge refers to the edge of the object passing nearest the top end of the sensors i e the top of the light screen farthest from the sensor s cabled end Each scan begins six beams prior to the last beam blocked during the previous scan The scan continues from this point and moves upward to the first unblocked beam where the scan is completed When the array is clear the system will execute straight scans Edge Scan begins again when a blocked channel is detected This scanning mode is designed to reduce sensing response time when measuring or locating only one edge of an object Use of the Edge Scan mode limits the scan analysis mode selection to Last Beam Blocked LBB Skip Scan reduces response time at the expense of decreased sensing resolution Skip Scan mode allows from one to seven beams to be skipped
45. nt modes C Suppress Header excluding the ALL mode Except for the ALL mode the analysis modes use two bytes C Compress Data to transmit the appropriate information For cases where the sensor cannot provide a result greater than 255 the Compress Data option will provide this data in one byte Figure A 2 Serial Communication Options As an example assume that you have a 48 channel sensor with a last beam blocked of 35 and a controller ID of B Assume two binary format options The first option is the standard Binary Transmission format The second format will use the Suppress Header and Compress Data options The two strings would be as follows Option 1 Binary Transmission Oxic B 0x00 0x23 a total of 5 bytes per scan Option 2 Binary Transmission Suppress Header Compress Data 0x23 1 byte per scan Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 41 MINI ARRAY Instruction Manual Notes Banner Engineering Corp Minneapolis MN U S A 8 wee a www bannerengineering com Tel 763 544 3164 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 de
46. olts and one NPN transistor output MACI 1 Two linear sinking analog current outputs 4 to 20 mA and one NPN transistor output Models MAC16N 1 and MAC16P 1 e Two additional measurement modes TRN mode counts the number of clear to blocked and blocked to clear transitions SEG mode partitions the array into up to 16 regions e Controller has flexible blanking capabilities with unlimited blanking conditions Blanking may be set automatically Auto Blanking or specified using the supplied PC software MAC16N 1 16 discrete open collector NPN current sinking transistor outputs MAC16P 1 16 discrete open collector PNP current sourcing transistor outputs Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 5 MINI ARRAY Instruction Manual System Overview 1 1 2 Sensing Response sensing response is a function of the number of beams interrogated i e steps per scan of the array The time per step is 55 us 0 000055 seconds As a result dense arrays i e 3 8 beam spacing yield the highest sensing resolution while arrays with wider 3 4 beam spacing offer faster sensing response 1 1 4 Supplied System Software The supplied software program used to configure each System control module may be run on any PC running Windows XP Vista or 7 The menu driven program walks the user through the many scanning and output options After the desi
47. onfiguration 9 9 4 Blanking Specifications A Blanking feature allows areas of the array to be blanked made blind to activity within an area Models MAC 1 MACP 1 MACN 1 MACV 1 and MACI 1 Blanking specifications allow either one or two areas of the array to be blanked made blind to activity within that area Beams are numbered from the bottom cable end of the sensors to the top of the sensors The Low beam number and the High beam number can be designated to define a Field to be blanked see Figure 5 14 Zeros are used as default settings to signify no blanking PSF Configuration Analysis Mode Selection Control Mode Selection Blanking Specifications Meas1 om mg ate Meas2 None Host Mode gt o o Senal Communi Serial Transmission Straight No Serial Communication Baud Interlaced 3600 ASCII Transmission ey Edge e Suppress Clear Data Skip Output 2 Analog Output B lanking 5 pecifications Suppress Meader Discrete Outputs Alarm 5 2 Compreys Data Analysi Output ii Field Low High Analys Sfan 8 Invert Y M Output 2 Disable Figure 5 14 MINI ARRAY software blanking specifications models MAC 1 MACP 1 MACN 1 MACV 1 and MACI 1 Models MAC16P 1 and MAC16N 1 The controller can specify blanking of any light channel and save these specifications in static memory Blank
48. onnection points see Figure 3 4 3 2 Controller Mounting The controller must be installed inside an enclosure with a NEMA or IEC rating suitable for the operating environment Mounting dimensions for the controller are shown in Figure 2 2 The controller is supplied with M3 5 x 0 6 hardware for direct mounting to a surface or it can be mounted onto standard 35 mm DIN rail 3 3 Emitter and Receiver Hookups Emitter and receiver cables connect in parallel to controller terminals 4 through 8 Connect the wires from both sensor cables as follows Terminal 4 Brown Terminal 5 Blue Terminal 6 Bare Terminal Black Terminal 8 White Trim off the foil shield and the braided shield at the point where the wires exit the cable see Figure 3 4 MINI ARRAY Instruction Manual 0 32 max 0 5 13 mm radius minimum bend Figure 3 3 Quick disconnect cable clearances Trim braided shield flush with cable Trim foil shield flush with cable Uninsulated drain wire The drain wire is the uninsulated stranded wire which runs between the braided shield and the foil shield Remove the foil shield and braided shield at the point where the wires exit the cable Figure 3 4 Emitter receiver cable preparation Banner Engineering Corp Minneapolis MN U S A 14 P N 43298 rev E www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual Installation and Mechanical Alignment 3 4
49. ore beams are blocked within any segment the output corresponding to that segment will respond Transition TRN controller models MAC16N 1 and MAC16P 1 only The controller counts transitions which are used to count objects This mode counts both clear to blocked and blocked to clear transitions For example if an object blocks beams 20 through 30 the TRN mode will count two transitions If an additional object blocks beams 35 through 40 then the TRN mode will count four transitions Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E MINI ARRAY Instruction Manual Last Beam Made First Beam Made BMRL 3616A BMEL 3616A Emitter 0 In Last Beam Made Mode last beam is 37 of 48 24 In First Beam Made Mode first beam is 26 of 48 Last Beam Blocked First Beam Blocked BMRL 3616A Receiver BMEL 3616A Emitter 48 In Last Beam Blocked Mode last beam is 43 of 48 In First Beam Blocked Mode 16 first beam is 15 of 48 Total Beams Made Total Beams Blocked BMEL 3616A Emitter fi 48 in Total Beams Made Mode 34 of 48 possible beams are 4 40 made 32 24 in Total Beams Blocked Mode 14 of 48 possible beams are 16 blocked J 8 y 2 Figure 5 13 Examples of MINI ARRAY scan analysis modes MINI ARRAY Instruction Manual Controller C
50. ough the internal circuitry of the emitter and receiver can withstand heavy impulse forces vibration isolators can be used instead of the M4 bolts to dampen impulse forces and prevent possible damage from resonant vibration of the emitter or receiver assembly Two different Anti Vibration Mounting Kits are available from Banner as accessories P N 48955 consists of 4 anti vibration M4 x 10 mm mounts M4 x 0 7 x 9 5 mm and 8 Slotted Hex Head M4 Keps nuts These mounts are made with Compression from BUNA N rubber and are more Washer 2 resistant to chemicals and oils P N 12847 consists of 4 anti vibration mounts M4 x 0 7 x 9 5 mm and 8 M4 Keps nuts These mounts are made from natural rubber which are less chemically resistant than the 48955 Mounting mounts but have a greater sheer force Surface Spec at higher temperature Mounting Bracket M4 Nut 4 Torque to 12 in Ibs 1 3 N m Emitter or Receiver Compression Washer 4 Mounting Bracket Washer Figure 3 1 MINI ARRAY emitter and receiver mounting hardware Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 13 Installation and Mechanical Alignment Mount the emitter and receiver in their mounting brackets shown in Figure 3 1 and position the red lenses of the two units directly facing each other The connector ends of both senso
51. re 6 1 The red LED ON indicates that the emitter has power applied and is functioning properly If the red LED is OFF there has been an emitter failure The red DIAG 3 indicator on the controller should come ON whenever the red LED on the emitter goes OFF Run the Diagnostics software see Section 6 3 to determine the cause of the emitter failure A flashing red emitter LED indicates that the emitter has momentarily lost and then regained power and is waiting for activity from the controller This can occur in Gate or Host Mode after the emitter has been temporarily unplugged and then reconnected but before the emitter receives its next gating command Receiver Figure 6 1 The green LED ON only indicates proper alignment and no beams broken Yellow Figure 6 1 MINI ARRAY sensor status indicator LEDs A flashing green only indicator has the same meaning as a flashing red emitter indicator as described above Green and yellow ON together indicates marginal alignment The MINI ARRAY system will continue to operate normally but the yellow comes ON as an early warning of possible signal loss due to gradual sensor misalignment and or dirt buildup on the lenses etc The red LED ON only indicates either one or more beams blocked or sensor misalignment if the screen is clear of objects All three LEDs yellow red and green ON at the same time indicates a receiver failure Run the Diagnostics software see Section 6 3 to de
52. red options are selected the user can save the combination of selections in a Parameter Setup File PSF and store it in the control module s non volatile memory Any number of PSFs may be stored in the computer and recalled as needed The software also provides alignment and diagnostics routines An Alignment screen displays the individual status of each beam in the light screen as well as the total number of beams in the System and totals of beams blocked made and blanked Built in system diagnostics can be used to assess emitter and receiver hardware errors Banner Engineering Corp Minneapolis MN U S A e a a www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual System Overview 1 2 System Components Emitter Receiver 1 2 1 Emitter and Receiver Models Emitter Receiver Total Models Array Length Beams BMEL616A BMRL616A 133 5 25 User Supplied PC Configure and monitor the System with the supplied software and a PC compatible computer see Section 1 1 4 BMEL1216A BMRL1216A 286 11 25 BMEL1816A BMRL1816A 438 17 25 BMEL2416A BMRL2416A 591 23 25 BMEL3016A BMRL3016A 743 29 25 BMEL3616A BMRL3616A 895 35 25 BMEL4216A BMRL4216A 1048 mm 41 25 BMEL4816A BMRL4816A 1200 mm 47 25 DIN Rail Mountable Control Module BMEL6016A BMRL6016A 1505 59 25 BMEL7216A BMRL7216A
53. rs must point in the same direction Measure from one or more reference planes i e the floor to the same points on the emitter and receiver to verify their mechanical alignment If the sensors are positioned exactly vertical or exactly horizontal a carpenter s level may be useful for checking alignment Extending a straight edge or a string between the sensors may help with positioning Also check by eye for line of sight alignment Make any necessary final mechanical adjustments and hand tighten the bracket hardware See Section 5 for information on alignment indicators and the use of the alignment software supplied with the controller NON QD END 6 266 2 06 8mm 188 2 4 8mm 21 2 930 5mm Slots have clearance for M4 bolts supplied and allow 30 rotation Full R 4 25 R 6 4mm 47 11 9mm 34 8mm 97 24 6mm Material Cold rolled steel 2 12 Finish Black zinc plated 53 8mm chromate dip 40 2 10 2mm Min R ur d Figure 3 2 MINI ARRAY emitter and receiver mounting bracket dimensions Connect the shielded cables to the emitter and receiver and route them to the controller location Follow the local wiring code for low voltage dc control cables The same cable type is used for both emitter and receiver two cables required per system Cut the cables to length after making sure they are routed properly Remove cable braid at the controller c
54. s follows Din AD Number of DB 9 FUNCTION 2 Transmit TX Receive RX Ground GND NOTE DO NOT use a null modem RS 232 cable Configure the COM port of the PC by first selecting the Options menu see Figure Hep 5 1 The program supports serial communication via the COM1 COM20 port Serial Port of the computer Select Options then select Serial Port or Enter Select either v COM2 COM1 or COM2 Check Save Settings on Exit if it is not already checked to store the COM port selection Figure 5 1 MINI ARRAY software Option menu 0 2 Alignment Analysis Alignment status is continuously displayed by the green LED indicator on the Receiver and the controller When all unblanked beams are clear and excess gain of all beams is more than 3x the green alignment indicators will be ON When the excess gain of one or more beams drops to between 3x and 1x the green ALIGN LED on the controller will remain ON but the yellow LED on the receiver will come ON to indicate a warning of marginal alignment See Section 6 for more information about sensor alignment Mini Array Diagnostics F2 One feature of the MINI ARRAY software is a program that displays the status of oro each beam in the array This routine can be very helpful for final alignment or when Set Part Number analyzing how the MINI ARRAY is viewing objects in the sensing array To launch this Exit
55. scan initiation WARNING Supports serial communication with a computer or PLC via RS 232C interface enables a computer or PLC to process scan data and or initiate scans serial data may be either ASCII or binary Baud Fate Comtal Mode Sebectien ui prot 18 Mode pias e 5 Set Pant PEIN Hode Low High Lum High 868 Dapa Ei Disabled s Dipa 82 m EE eger soa ae 8 es can B Multinle Ugipul HIRLAHRAY PSF Caonbgeralon Sena C Controls 10 a _ Terna an a No Sejal Communicati Measurement Mods Mexal T AJ Hode Tianimittian m rz E Scanning Mathod Not To Be Used for Personnel Protection Senal Upon Never use these products as sensing devices for personnel protection Doing so could lead to serious injury or death These sensors do NOT include the self checking redundant circuitry necessary to allow their use in personnel safety applications A sensor failure or malfunction can cause either an energized or de energized sensor output condition Consult your current Banner Safety Products which meet OSHA ANSI and IEC standards for personnel protection Printed in USA 04 12 P N 43298 rev F Contents Table of Contents 1 System Overview
56. tate Channels in the checked state are blanked Select All Channels Current Channel Blanks 56 lected Clear Selected Cancel Figure 5 15 Channel Blanking Edit screen models MAC16P 1 and MAC16N 1 The Channel Blanking Edit Screen groups the beams into rows with a check box for each beam For instance the first row is labeled 1 16 The first check box represents the blanking state of channel 1 The user can move the cursor over any check box and click the left mouse button to select blanking for that channel A check mark indicates that the channel has been selected for blanking The Blank Selected Clear Selected feature allows the user to select clear rows of channels The OK button adds the new blanking additions to the Alignment screen The Cancel button voids the Edit changes Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 30 43298 rev E MINI ARRAY Instruction Manual Controller Configuration 9 9 9 scanning Methods The control module may be configured for one of four available scanning methods a Straight see Figure 5 16 C Interlaced Straight Scan is the default mode in which all beams are scanned in sequence from Edge the bottom end cable end to the top end of the sensors C Skip Interlaced Scan alternates a straight scan with a slanted beam scan A slanted beam scan begins with a beam established between the emitter s second cha
57. termine the cause of the receiver failure Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 P N 43298 rev E 35 MINI ARRAY Instruction Manual System Operation 6 2 Controller Operating Status Indicators Models MAC 1 MACP 1 MACN 1 displays the status of Output 1 MACV 1 MACI 1 Models MAC16N 1 16 1 displays the status that at least one output is active Models MAC 1 displays the status of Output 2 Output 2 may be assigned to an Analysis Mode or may be used as a system diagnostics MACP 1 MACN 1 MACV 1 MACI 1 ai as a Trigger alarm for gating another MINI ARRAY Models MAC16N 1 MAC16P 1 displays the status of Output 16 All Models displays the status of the Gate input indicates proper sensor alignment and a clear light screen This Green All Models indicator is ON when the green or green and yellow LEDs of the receiver are ON All Models used in combination to indicate system status as shown below Normal Receiver Controller Condition Error Mismatch Error Error Error ow o om or or om me oe om or o Pom J or m mj or or o Jj m o m Figure 6 2 Controller front panel Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 36 P N43298 rev E MINER System Operation 6 3 Diagnostics Program
58. tinuing in sequence to the top end of the sensor Last Beam Blocked LBB The controller identifies the location of the last beam blocked Total Beams Blocked TBB The controller totals the number of blocked beams Contiguous Beams Blocked CBB The controller totals the number of contiguous beams blocked in each group of blocked beams along the length of the light screen and registers the maximum value First Beam Made FBM The controller identifies the location of the first clear beam Last Beam Made LBM The controller identifies the location of the last clear beam Total Beams Made TBM The controller totals the number of clear beams Contiguous Beams Made CBM The controller totals the number of contiguous clear beams in each group of clear beams along the length of the light screen and registers the maximum value Vehicle Separation VHS discrete output models only Controller output 1 is energized when six or more continuous inches of light screen length are blocked i e contiguous beams blocked and de energizes when all beams are clear This mode is typically used for vehicle sensing in toll booth applications Segment SEG controller models MAC16N 1 and MAC16P 1 only The controller segments the array into regions and allows the user to partition the array The user defines contiguous segments Once the segments are defined the Controller monitors each segment for blocked beams within each segment If one or m
59. ts will not change unless the condition is true for five consecutive scans Multiple Output MIMI AHH AY PSF Configuration Seral Communication Conto 1 Baud Rate Control Mode Selection gt Scanning Method Analysis Mode Selects Meas 1 Meas 2 Senal Transmssion Setup Mo Serial Communication Measurement Mode Result All Mode Tranzmizzion Type Binary Senal Options Suppress rc Cancel Upload PSF Execute Outputs File Save PSF File Achieve Figure 5 10 PSF Configuration screen models MAC16P 1 and MAC16N 1 P N 43298 rev E Edit Discrete Outputs E Set Point Hysteresis Measurement Low High ig Cancel Output 1 Meas 1 Inverted 1 Output 2 Scan 8 Output 3 M 1 j Output 4 Output 5 Output 6 Output 7 M Output 8 M Output 9 Output 10 M Output 11 M M E M ccc Nw CO o Output 15 Meas1 Output 16 Meas1 Figure 5 11 Edit Discrete Outputs screen Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual Controller Configuration MACV 1 and MACI 1 Analog Outputs The MACV 1 and MACI 1 Controllers offer two independent analog outputs See Figure 5 9 For Analog Output 1 and Analog Output 2 each output is assigned to one of six analysis modes whi
60. ui nur 21 9 4 Parameter Setup Files 5 5 22 9 9 Creating New Parameter Setup Files 5 5 25 5 5 1 Analysis Mode 510 20 9 9 2 Output Programming dha eaa e MC dive Guan 25 5 5 3 Analysis Mode 5 20 5 5 4 Blanking 5 5 29 5 5 5 Scanning do added Eo iran 31 5 5 6 Control Mode Selection 32 5 6 Serial 32 5 7 PSF Assignment and 33 6 System page 35 6 1 Sensor Operating Status Indicators 35 6 2 Controller Operating Status 36 6 3 Diagnostics Program 3 No e CR E RE page 39 Host WiOGeGOMMARG a cour ns daro rt ITEE AEE NENN 39 Serial Data Format suae amp bes Sede eee Shae mana 39 Banner Engineering Corp Minneapolis MN U S A MINI ARRAYS Instruction Manual www bannerengineering com Tel 763 544 3164 MINI ARRAY Instruction Manual System Overview 1 System Overview
61. ut and output response of the MAC controller is programmed using the PSF Configuration screen shown in Figure 5 5 models MAC 1 MACN 1 MACP 1 MACV 1 and MACI 1 and Figure 5 6 models MAC16N 1 and MAC16P 1 To access the PSF Configuration screen select Edit PSF under the MINI ARRAY Main menu Figure 5 2 or press the F4 key The chart on page 24 lists the programmable functions Section 5 5 describes them in detail PSF Configuration Control Mode Selection Continuous Gate Host Mode Analysis Mode Selection Meas Meas2 sett Senal Communication 9600 Straight Baud Rat Interlaced aa ee Controller ID Analog Output Analysis Mode Output 1 Disabled s Output 82 Disabled Ea Discrete Outputs Analysis Mode Output 1 Disabled s Output 82 Disabled Output 2 Other Features Alarm Trigger 5 Invert Y 7N m CNN Low High Low Hysteresis Blanking Specifications Field Low High o o 2 o Serial Transmission No Serial Communication ASCII Transmission Suppress Clear Data e Binary Transmission gt Suppress Clear Data ze Suppress Header Compress Data Scan 8 Invert Y 7N B8 82 File Retreive PSF Figure 5 5 MINI ARRAY software PSF Configuration models MAC 1 MACP 1 MACN 1 MACV 1 and MACI 1 Hultiple Dutput MINI
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