a-gage® high-resolution mini-array® instruction manual
TRANSCRIPT
High-Resolution MINI-ARRAY Features• Excelsathigh-speed,preciseprocessmonitoringandinspectionapplications
• Acomprehensivecombinationofscanningmodesandoutputs:
–10measurement(“ScanAnalysis”)modes –3scanningmethods –Beamblanking –Selectablecontinuous,gatedorhost-controlledscaninitiation
–Programmablehysteresisforhighandlowlimits
–Serialcommunicationoptions• Storablescanningprogramseliminatereprogrammingforrepeatedapplications
• Non-volatilememorystoresalignmentsettings
• AllmodelswithbothAnalogandDiscreteoutputs
• AnalogoutputNullsetting• Lowcost,comparedwithsimilarsystems• Precisionsensorshavea380mmto1.8m(15"to6')workingrange
• Widefieldofview,easilyaligned• Alignmentroutineequalizesgainofeachbeamforreliable2.5mm(0.10")objectdetectionthroughoutthearray
• HostcomputerorPLCmaybeusedtoinitiatescansand/orprocessscandata
• Uniqueaddressesforupto15controlmodulesononeEIA-485PartyLine
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A-GAGE® High-Resolution MINI-ARRAY® Instruction ManualFor controllers with 2 analog and 2 discrete outputs
Printed.in.USA. 04/12 P/N 64118 rev.C
971410thAvenueNorth•Minneapolis,MN55441Phone:763.544.3164• Fax:763.544.3213
Email:[email protected]
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WARNING . . .Not To Be Used for Personnel Protection
ThesesensorsdoNOTincludetheself-checkingredundantcircuitrynecessarytoallowtheiruseinpersonnelsafetyapplications.Asensorfailureormalfunctioncancauseeitheranenergizedorde-energizedoutputcondition.ConsultyourcurrentBannerSafetyProductscatalogforsafetyproductswhichmeetOSHA,ANSIandIECstandardsforpersonnelprotection.
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P/N64118rev.B2Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164
3Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164
P/N64118rev.B
Table of Contents
Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164
1. System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 SystemComponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 SystemFeatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.3 TypicalApplications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.1 EmitterandReceiverSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2 ControlModuleSpecifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Installation and Mechanical Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1 EmitterandReceiverMounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.2 ControlModuleMounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.3 Hookups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.3.1 EmitterandReceiverHookups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3.2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3.3 Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. Software Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Control Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1 CommunicationsSetup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1.1 PingRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1.2 FactorySettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2 SystemAlignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.1 Push-buttonAlignmentRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.2 SoftwareAlignmentRoutine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.2.3 Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.3 ProgrammingControlModuleResponse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5.3.1 SelectedControllerandSerialConnection. . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3.2 ControlModeSelection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3.3 ScanningMethod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.3.4 ScanAnalysisModeSelection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.3.5 AnalogOutputConfiguration(AnalysisModeAssignment). . . . . . . . . . . . 26 5.3.6 ZeroValue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3.7 DiscreteOutputConfiguration(AnalysisModeAssignment). . . . . . . . . . . 28 5.4 SerialCommunicationwithaHostController . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.1 SerialDataTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.2 TransmissionType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.3 SerialOptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.5 TransferofPSFtotheControlModule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.5.1 SavingandRecallingPSFFiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5.2 PSFOutputAnalysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5.3 QuitandExit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6. System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1 DiagnosticsIndicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.2 DiagnosticsRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix A: Data Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.1 HostModeCommandString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.2 SerialDataFormatandHeaderString . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.2.1 ASCIIFormatDataTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A.2.2 BinaryFormatDataTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A.3 MaxMeasureModeCommandString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Appendix B: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
P/N64118rev.B
System Description
4Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164
1. System Description
TheA-GAGE®High-ResolutionMINI-ARRAY®measuringlightscreenisidealforapplicationssuchason-the-flyproductsizingandprofiling,edge-guidingandcenter-guiding,looptensioningcontrol,holedetection,partscountingandsimilaruses.
1.1 System Components
AtypicalA-GAGEHigh-ResolutionMINI-ARRAYSystemhasfivecomponents:ahigh-resolutionemitter/receiverpair,eachwithquick-disconnect(QD)connectors;oneoffourcompactcontrolmodules;andquick-disconnectcablestoconnectthem.SoftwareisincludedtointerfaceanyPC-compatiblecomputer(runningWindows®X, Vista, or 7)withthecontrolmoduleforSystemconfiguration.AhostcomputerorPLCmaybeusedtocontroland/orreceiveinputfromtheSystem.
Sensorsareavailablein12arraylengthsfrom163mmto1951mm(6.4"to76.8"),in163mm(6.4")increments,aslistedinthetableonpage5.TheemitterhastwocolumnsofinfraredLEDsspaced5mm(0.2")apart.Thecolumnsareseparatedby7.5mm(0.3")andarestaggeredfromeachotherby2.5mm(0.1").Thereceiverisconfiguredoppositetotheemitter,withtheidenticallengthandbeamspacing.Thishigh-resolutionsensorpairiscapableofdetectinga12.7-mmlongby2.54-mmdiameter(0.5"by0.1"dia.)cylindricalrod(heldperpendiculartothesensor).Thesensorshaveawidefieldofviewandareeasilyaligned,withaworkingrangeof380mmto1.8m(15"to6').
Eachofthefourversatilemicrocontroller-basedcontrolmodulesareconfiguredusingaPC-compatiblecomputerrunningWindows XP, Vista, or 7,andthesuppliedsoftware,viathebuilt-inRS-232interface.
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P/N64118rev.B
System Description
Emitter/Receiver Model
MAHE64AEmitterMAHR64AReceiver 1626mm(64.0")
MAHE6AEmitterMAHR6A Receiver
MAHE77AEmitterMAHR77AReceiver 1951mm(76.8")
MAHE13A EmitterMAHR13A Receiver
MAHE19A EmitterMAHR19A Receiver
MAHE26A EmitterMAHR26AReceiver
MAHE32A EmitterMAHR32AReceiver
MAHE38AEmitterMAHR38A Receiver
MAHE45AEmitterMAHR45AReceiver
MAHE51AEmitterMAHR51AReceiver
MAHE58AEmitterMAHR58AReceiver
MAHE70AEmitterMAHR70AReceiver
Array Length Y*
163mm(6.4")
325mm(12.8")
488mm(19.2")
650mm(25.6")
813mm(32.0")
975mm(38.4")
1138mm(44.8")
1300mm(51.2")
1463mm(57.6")
1788mm(70.4")
640
768
Total Beams
64
128
192
256
320
384
448
512
576
704
Emitter and Receiver Models
Cables
Configure and monitor the System with the supplied software and any PC-compatible computer (running Windows® XP, Vista, or 7), via an RS-232 cable.
High-Resolution Receiver
High-Resolution Emitter
DIN-Rail Mountable Control Module
Figure 1-1. A-GAGE High-Resolution MINI-ARRAY System components
Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164
ControllerModel
Solid-StateDiscrete Outputs
Analog Outputs
MAHCVP-1 2PNP (2)0-10VSourcing
MAHCVN-1 2NPN (2)0-10VSourcing
MAHCIP-1 2PNP (2)4-20mASinking
MAHCIN-1 2NPN (2)4-20mASinking
Quick-Disconnect Cables
Communication Cables
CableModel Description
Sensor CablesQDC-515C 4.6m(15')Cable,straightQDconnector
QDC-525C 7.6m(25')Cable,straightQDconnector
QDC-550C 15.2m(50')Cable,straightQDconnector
Communication CablesMASC 2m(6.5')DB9,straightRS-232cable
Control Module Models
P/N64118rev.B
System Description
6
Figure 1-2. A-GAGE High-Resolution MINI-ARRAY System features
1.2 System Features
Built-infeaturessimplifytheoperationoftheA-GAGEHigh-ResolutionMINI-ARRAYsystem.High-resolutionemittersandreceivers,availablein12lengths,featuretwocloselyspacedcolumnsofbeamstoprovideaprecise,high-resolutionlightscreenforexactingapplications.TheAlignmentroutineautomaticallyequalizestheexcessgainofeachbeamforreliable2.5-mm(0.10")objectdetectionthroughoutthearrayandstoresthisdatainnon-volatilememory.TheAlignmentroutineneednotbeperformedagainunlessthesensingapplicationchanges,oriftheemitterand/orreceiverismoved.Programmablebeamblankingaccommodatesmachinecomponentsorotherfixturesthatmustremaininormovethroughthelightscreen.Blankingmaybesetautomaticallyaspartoftheinitialsetup,orbyusingtheincludedconfigurationsoftware.
Built-indiagnosticprogrammingandeasy-to-seeindicatorsonthesensorsandthecontrolmodulemakealignmentandtroubleshootingeasy(Figure1-2).TheemitterhasaredLEDthatsignalsproperoperation.ThereceiverhasthreebrightLEDs:greensignalsthatthesensorsareproperlyaligned;yellowsignalsmarginalalignment;andredsignalsmisalignmentorablockedcondition.Thecontrolmodulehasfourstatusindicators:3redLEDssignaldiscreteoutput#1conducting(seesection5.3.5formoreinformationonoutputs),Alarmoutput(discreteoutput#2)conducting,andgatesignalreceived;agreenLEDsignalsthatthesensorsareproperlyaligned.AsegmentedLEDDiagnosticsIndicatorprovidesdetailedsystemstatususingsingle-digitcodes;a“period”intheindicatorwindowindicatesthepresenceofblanking.Akeytothediagnosticscodesisprintedonthesideofthecontrolmoduleforsimplifiedtroubleshooting.
TheA-GAGEHigh-ResolutionMINI-ARRAYSystemprovidesawideselectionofsensingandoutputoptions,including:measurement(“scananalysis”)modesandscanningmethodsthatcandeterminethetargetobject’slocation,overallsize,totalheightortotalwidth.Scanningmaybecontinuousorcontrolledbyahostprocesscontrolleroragatesensor.Upto15systemsmaybenetworked.
High-Resolution Emitter
DIN-Rail-Mountable Control Module
High-Resolution Receiver
HIGH RESOLUTION MINI-ARRAY CONTROLLER
ALIGNMENTSWITCH
POWER
POWER
DIAGNOSTICSINDICATOR
2 - TX3 - RX5 - COM
RS-232
MAHCVP-1
OUTP
UT
ALAR
M
GATE
ALIG
N
1
+ –
+ –
16-30V dc1A MAX
10-30VDCGATE
D OUT 1 150mA MAX
0-10VOLTS25mA (MAX)
V OUT 1
EMTR RCVR
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1 +12V COM DRN T/R T/R
BR BU BK WH
TX TX+ –
10-30VDCALIGN
0-10VOLTS25mA (MAX)
V OUT 2+V
ALARM150mA MAX
+V
7.6 mm (0.30")
2.5 mm(0.10")
5.1 mm(0.20")
Diagnostics Indicator
Alignment Button
Red Discrete Output #1 LED
Red OperationalLED
Green Alignment LEDRed Blocked LED
Yellow MarginalAlignment LED
Red Alarm (Discrete Output #2) LEDRed Gate LED
Green Align LED
RS-232 Port
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P/N64118rev.B
System Description
Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164
Figure 1-3. Typical applications for the A-GAGE High-Resolution MINI-ARRAY System
Log Profiling for Lumber Optimization Box Profiling
Maintaining Centering of Opaque Rolled Goods Inspection Applications
Supplied System SoftwareThesuppliedHRMAsoftwareprogram,usedtoconfigureeachSystemcontrolmodule,mayberunonanyPC-compatiblecomputerrunningWindows®XP, Vista, or 7..Themenu-drivenprogramwalkstheuserthroughthemanyscanningandoutputoptions.Afterthedesiredoptionsareselected,theusercansavethecombinationofselectionsinaParameterSetupFile(PSF),andstoreitinthecontrolmodule’snon-volatilememory.AnynumberofPSFsmaybestoredinthesystemconfigurationcomputerandrecalledasneeded.
Thesoftwarealsoprovidesalignmentanddiagnosticsroutines.AnAlignmentscreendisplaystheindividualstatusofeachbeaminthelightscreen,aswellasthetotalnumberofbeamsintheSystem,andtotalsofbeamsblocked,madeandblanked.Built-insystemdiagnosticscanbeusedtoassessemitterandreceiverhardwareerrors.
1.3 Typical Applications
P/N64118rev.B
Specifications
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Environmental Rating
Minimum Object Sensitivity 2.5mm(0.1")
NEMA4,13(IP65)
Sensor Scan Time 1.8millisecondsto58.4milliseconds,dependingonscanningmethodandsensorlength;seeSection5.3.3fordetailedinformation
Power Requirements 12Vdc±2%,suppliedbycontroller
Status Indicators Emitter: RedLEDlightstoindicateproperemitteroperationReceiver: Greenindicatessensorsaligned Yellowindicatesmarginalalignmentofoneormorebeams Redindicatessensorsmisalignedoroneormorebeam(s)blocked
Connections Sensorsconnecttocontrollerusingtwo5-conductorquick-disconnectcables(oneeachforemitterandreceiver),orderedseparately.Seepage5foravailablelengths.UseonlyBannercables,whichincorporatea“twistedpair”fornoiseimmunity.Cablesmeasure8.1mm(0.32")indiameterandareshieldedandPVC-jacketed.Conductorsare20gauge(0.9mm).Emitterandreceivercablesmaynotexceed75m(250')long,each.
Construction Aluminum,withblackanodizedfinish;acryliclenscover
Operating Conditions Temperature:0°to+50°C(+32°to122°F)Maximum relative humidity:95%at50°C(non-condensing)
Emitter/Receiver Range 380mmto1.8m(15"to6')
2. Specifications
2.1 Emitter and Receiver Specifications
Certifications
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P/N64118rev.B
10.2 mm(0.40")
L3
38.1 mmSquare(1.50")
53.8 mm(2.12")
2.5 mm(0.10")
18.3 mm(0.72")
47.2 mm(1.86")
L1
71 mm(2.8")
R13 mm (0.5")Minimum Bend
L2
Figure 2-1. Emitter and receiver dimensions
With mounting bracket flanges “in”With mounting bracket flanges “out”
Emitter/Receiver Model
Housing Length Distance Between Bracket Holes
MAHE6AEmitterMAHR6A Receiver 236mm(9.3") 268mm(10.5")
MAHE13A EmitterMAHR13A Receiver 399mm(15.7") 430mm(16.9")
MAHE19A EmitterMAHR19A Receiver 561mm(22.1")
MAHE26A EmitterMAHR26AReceiver 724mm(28.5") 756mm(29.7")
MAHE32A EmitterMAHR32AReceiver 887mm(34.9") 918mm(36.2")
MAHE38AEmitterMAHR38A Receiver 1049mm(41.3")
MAHE45AEmitterMAHR45AReceiver 1215mm(47.8") 1246mm(49.1")
MAHE51AEmitterMAHR51AReceiver 1377mm(54.2") 1409mm(55.5")
MAHE58AEmitterMAHR58AReceiver 1540mm(60.6") 1572mm(61.9")
MAHE64AEmitterMAHR64AReceiver 1703mm(67.0") 1734mm(68.3") 1677mm(66.0")
1515mm(59.6")
1189mm(46.8")
1024mm(40.3")
861mm(33.9")
699mm(27.5")
536mm(21.1")
373mm(14.7")
211mm(8.3")
MAHE70AEmitterMAHR70AReceiver 1865mm(73.4") 1897mm(74.7")
MAHE77AEmitterMAHR77AReceiver 2028mm(79.8") 2060mm(81.1") 2003mm(78.8")
1840mm(72.4")
L1 L2 L3
593mm(23.3")
1081mm(42.6")
1352mm(53.2")
Specifications
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P/N64118rev.B
Specifications
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Status Indicators
Power Requirements [email protected](typical:0.5A@16Vdc)
Output 1 (red): LightstoindicateDiscreteOutput#1isactiveAlarm (red): LightstoindicateDiscreteOutput#2isactiveGate (red): LightstoindicateGATEinputisactiveAlign (green): LightstoindicateemitterandreceiverarealignedDiagnostics indicator: (Keyoncontrollersidelabel)IdentifiesSystemerrorsandstatus
Inputs Sensor input: Emitterandreceiverwireinparalleltofiveterminals.Gate input: Opticallyisolated,requires10to30Vdc(7.5kΩimpedance)forgatesignalRemote alignment input: Opticallyisolated,requires10to30Vdc(7.5kΩimpedance)foralignment
sequencesignal
Discrete (Switched) Outputs NPN outputs:OpencollectorNPNtransistorratedat30Vdcmax.,150mAmax.PNP outputs: OpencollectorPNPtransistorratedat30Vdcmax.,150mAmax.All discrete outputs: OFF-state leakage current: <10µA@30Vdc ON-state saturation voltage: <1V@10mAand<1.5V@150mA
Serial Data Outputs RS-232orRS-485interface.(Upto15controlmodulesmaybegivenuniqueaddressesononeRS-485partyline.)ASCIIorbinarydataformat9600,19.2K,or38.4Kbaudrate8databits,1stopbit,andeven,odd,ornoparity
Analog Outputs Voltage-sourcing outputs:0to10Vdc(25mAcurrentlimit)Current-sinking outputs:4to20mA(16to30Vdcinput)Resolution: Span/NumberofsensingchannelsLinearity:0.1%offullscaleTemperature variation:0.01%offullscaleper°C
System Programming ViaRS-232interfacetoPC-compatiblecomputerrunningWindows®XP, Vista, or 7andusingsoftwaresuppliedwitheachcontrolmodule.
Construction Polycarbonatehousing;mountstoflatsurfaceordirectlyonto35-mmDINrail
Environmental Rating Control Module:NEMA1,IECIP20Emitter/Receiver:NEMA4,13;IECIP65
Output Configuration MAHCVP-1:TwoPNPdiscrete(switched),two0-10VvoltagesourcingMAHCVN-1: TwoNPNdiscrete(switched),two0-10VvoltagesourcingMAHCIP-1:TwoPNPdiscrete(switched),two4-20mAcurrentsinkingMAHCIN-1:TwoNPNdiscrete(switched),two4-20mAcurrentsinking
2.2 Control Module Specifications
Operating Conditions Temperature:0°to+50°C(+32°to122°F)Maximum relative humidity:95%@50°C(non-condensing)
Certifications
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P/N64118rev.B
81.0 mm(3.19")
115.0 mm(4.53")
106.0 mm(4.17")
35.0 mm(1.38")
DIN mounting slot
Slot for M3.5 screws (2)5.5 mm(0.22")
69.0 mm(2.72 ")
5.0 mm(0.20")
96.0 mm(3.78")
Figure 2-2. Control module dimensions
Specifications
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P/N64118rev.B
Installation and Mechanical Alignment
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www.bannerengineering.com•Tel:763.544.3164
3. Installation and Mechanical Alignment
3.1 Emitter and Receiver Mounting
BannerMINI-ARRAYemittersandreceiversaresmall,lightweight,andeasytohandleduringmounting.Themountingbrackets(supplied)allow±30°rotation.
Fromacommonpointofreference,makemeasurementstolocatetheemitterandreceiverinthesameplanewiththeirmidpointsdirectlyoppositeeachother.MounttheemitterandreceiverbracketsusingthevibrationisolatorsandM4Kepsnuts(allsupplied).SeeFigure3-1.StandardM4or#8-32boltsmaybesubstituted(andthevibrationisolatorseliminated)insituationswheretheemitterandreceiverarenotsubjectedtoshockorvibrationforces.Whiletheinternalcircuitsoftheemitterandreceiverareabletowithstandheavyimpulseforces,thevibrationisolatorsdampenimpulseforcesandpreventpossibledamageduetoresonantvibrationoftheemitterorreceiverassembly.
Figure 3-1. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting hardware
MountingSurface
M4 KepsNut (8)
M4 x 10 mm Slotted Hex Head with Com pres sion
Washer (2)
MountingBracket
Emitter orreceiver
Anti-Vibration Mount (4)
Mounting Bracket
Washer
Nut
Studs: M4 x 0.7 9.5 mm (0.38") long
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P/N64118rev.B
NON-QD EndQD End
Min. R.
Full R (4)
4.8 mm (2)(0.19")
38.1 mm(1.50")
6.4 mm R(0.25")
44.5 mm(1.75")
6.4 mm(0.25")
57.2 mm(2.25")
3.8 mm(0.15")
10.2 mm (2)(0.40")
ø30.5 mm(1.20")
34.8 mm(1.37")
11.9 mm(0.47")
Slots have clearancefor M4 bolts (supplied)
and allow ±30° rotation
ø13.2 mm(0.52")
ø6.8 mm (2)(0.27")
3.0 mm(0.12")
24.6 mm(0.97")
53.8 mm(2.12")
Material: Cold Rolled SteelFinish: Black, Zinc Plated
Chromate Dip
Figure 3-2. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting bracket dimensions
Installation and Mechanical Alignment
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Mounttheemitterandreceiverintheirbracketsandpositiontheredlensesofthetwounitsdirectlyfacingeachother.Theconnectorendsofbothsensorsmustpointinthesamedirection.Measurefromoneormorereferenceplanes(e.g.thebuildingfloor)tothesamepoint(s)ontheemitterandreceivertoverifytheirmechanicalalignment.Ifthesensorsarepositionedexactlyverticalorhorizontaltothefloor,acarpenter’slevelisusefulforcheckingalignment.Astraightedgeorastringextendedbetweenthesensorsalsohelpswithpositioning.Alsocheck“byeye”forline-of-sightalignment.Makeanynecessaryfinalmechanicaladjustments,andhand-tightenthebrackethardware.SeeSection6forinformationonalignmentindicatorsandSection5forinformationontheuseofthealignmentsoftwarewhichissuppliedwiththecontroller.
3.2 Control Module Mounting
ThecontrolmodulemustbeinstalledinsideanenclosurewhichhasaNEMA(orIEC)ratingsuitablefortheoperatingenvironment.
MountingdimensionsforthecontrollerareshowninFigure2-2,onpage11.ThecontrolmoduleissuppliedwithM3.5hardwarefordirectmountingtoasurface,orthemodulemaybemountedontostandard35mmDINrail.
P/N64118rev.B
Installation and Mechanical Alignment
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POWER
1
+ –
+ –
16-30V dc 1 A max
10-30V dcGATE
SIGNAL
+30V dc max
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROW
N
BLUE
DRAI
N (B
ARE)
BLAC
K
WHI
TE
DISCRETEOUTPUT#1
150 mAmax
EMITTER andRECEIVER CABLES
TX TX
DISCRETEOUTPUT#2 (ALARM)
+ –10-30V dc
ALIGN
RS-485
+30V dc max
150 mAmax
25 mAmax
0-10VANALOG
OUTPUT #2
25 mAmax
0-10VANALOG
OUTPUT #1
Figure 3-3. MAHCVN-1 hookup
POWER1
+ –
+ –
16-30V dc1 A max
10-30V dcGATE
SIGNAL
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROW
N
BLUE
DRAI
N (B
ARE)
BLAC
K
WHI
TE
DISCRETEOUTPUT#1
EMITTER andRECEIVER CABLES
TX TX
+ –10-30V dc
ALIGN
RS-485
150 mAmax
25 mAmax
0-10VANALOG
OUTPUT #2
25 mAmax
0-10VANALOG
OUTPUT #1
DISCRETEOUTPUT#2 (ALARM)
150 mAmax
Figure 3-4. MAHCVP-1 hookup
+30V dc max
POWER1
+ –
+ –
16-30V dc1 A max
10-30V dcGATE
SIGNAL
+30V dc
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROW
N
BLUE
DRAI
N (B
ARE)
BLAC
K
WHI
TE
EMITTER andRECEIVER CABLES
DISCRETEOUTPUT#2 (ALARM)
DISCRETEOUTPUT#1
+ –10-30V dc
ALIGN
Load
+16-30V
4-20 mAANALOGOUTPUT#2
4-20 mAANALOGOUTPUT#1
+16-30V
150 mAmax
150 mAmax
TX TXRS-485
Load
Figure 3-5. MAHCIN-1 hookup
+16 – 30V dc+16 – 30V dc
POWER1
+ –
+ –
16-30V dc 1 A max
10-30V dcGATE
SIGNAL
4-20 mAANALOGOUTPUT #1
4-20 mAANALOG
OUTPUT #2
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROW
N
BLUE
DRAI
N (B
ARE)
BLAC
K
WHI
TE
EMITTER andRECEIVER CABLES
DISCRETEOUTPUT#2 (ALARM)
+ –10-30V dc
ALIGN
Load Load
150 mAmax
DISCRETEOUTPUT#1
150 mAmax
TX TXRS-485
Figure 3-6. MAHCIP-1 hookup
3.3 Hookups
RefertoFigures3-4,3-5,3-6,and3-7fortheappropriatehookupinformation.
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P/N64118rev.B
2 - TX3 - RX5 - COM
RS-232
5 3 2
Installation and Mechanical Alignment
Serial Communication RS-232:AllA-GAGEHigh-ResolutionMINI-ARRAYSystemsmaycommunicatewitha
hostcomputerorcontrollerviaRS-232orRS-485serialprotocol.SeeSection5.3.1forselectablecommunicationsparameters.PrepareanRS-232cableusingamaleDB-9connectorwithconnectionsasshowninFigure3-8.
NOTE:DONOTusea“nullmodem”RS-232cable
RS-485: RS-485serialportislocatedatterminals#18(TX)and#19(TX).
DB-9 Pin # Function
2 Transmit(TX)
3 Receive(RX)
5 Ground(GND)
3.3.1 Emitter and Receiver Hookups
Emittersandreceiversconnecttogetherinparalleltoterminals#4through#8ofthecontrolmodule(identicalforallcontrolmodulemodels).SeeFigures3-3,3-4,3-5,and3-6forwirecolorinformation.
3.3.2 Inputs
System Power: Connectasourceof16to30Vdc,ratedat1amporgreater,tocontrolmoduleterminals#1(+)and#2(-).Connectagoodearthgroundtoterminal#3toprovideelectricalandRFnoiseimmunitytotheSystem.
NOTE:Removepowerbeforemakingotherconnectionstothecontroller.
Gate Signal: Asourceof10to30Vdcswitchedtoterminals#12(+)and#13(-)providesagatinginput(ifrequired).Thegatingvoltagetypicallyisswitchedbytheopen-collectoroutputtransistorofadcsensingdevice.ThegatesignalcontrolsscanningwhenoneoffourGateoptionsisselectedintheControlModeSelectionmenuofthePSFconfigurationroutine(seeSection5.3.2).
Align: Asourceof10to30Vdcswitchedtoterminals#14(+)and#15(-)providesaremotemeansofrunningtheautomaticalignmentandblankingroutines.TheswitchsequenceisidenticaltotheproceduredescribedinSection5.2.1fortheAlignment
switchonthefrontofthecontrolmodule.
Control ModuleAnalog Outputs
(Terminals #10 and 16)Discrete Outputs*
(Terminals #9 and 20)
MAHCVN-1Figure3-3
0to10VSourcing15mAmax.
NPNopen-collector30Vdcmax.150mAmax.
MAHCVP-1Figure3-4
0to10VSourcing15mAmax.
PNPopen-collector30Vdcmax.
MAHCIN-1Figure3-5
4to20mASinking
16to30Vdc
NPNopen-collector30Vdcmax.150mAmax.
MAHCIP-1Figure3-6
4to20mASinking
16to30Vdc
PNPopen-collector30Vdcmax.150mAmax.
*NOTE:DiscreteOutput#2islabeled“Alarm”onthecontrolmodule.Figure 3-8. DB-9 connections between the control module and the PC
Trim braided shield flushwith cable
Trim foil shield flushwith cable
Uninsulateddrain wire
Figure 3-7. Emitter and receiver cable preparation
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NOTE:The“drainwire”istheuninsulatedstrandedwirewhichrunsbetweenthebraidedshieldandthefoilshield.Thefoilshieldandthebraidedshieldshouldberemovedatthepointwherethewiresexitthecable.
3.3.3 Outputs
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4. Software InstallationThe High-Resolution MINI-ARRAY software CD includes an installation routine that quickly and easily loads the MINI-ARRAY configuration program into your computer. The High-Resolution MINI-ARRAY configuration program requires approximately 50 MB of hard disk space. Install as follows:
1. Use the Parameter Setup Software CD included with the controller, or download (www.bannerengineering.com) as required.
2. Insert the Software CD into the CD drive. If the program does not auto-start, browse to your CD drive, click Setup.exe, then select START, then select RUN.
2. The Welcome dialog box will appear. Select Next, and follow the prompts in the dialog boxes as they appear.
4. The installation program then decompresses the files. A status dialog box monitors the progress of the installation.
5. An Installation Completed dialog box appears. Select OK. Reboot your computer for the changes to take effect.
After the software is installed, a MINI-ARRAY shortcut icon is placed on your desktop. Double-click on the MINI-ARRAY icon to launch the program, then follow the configuration and setup procedures described in Section 5 of the primary manual.
Figure 4-1. MINI-ARRAY software installation: dialog boxes
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Figure 5-1. Options menu, serial port selection
Figure 5-2. MINI-ARRAY menu
Figure 5-3. Screen showing the result of a completed Ping routine
5. Control Module Configuration
TheA-GAGEHigh-ResolutionMINI-ARRAYcontrolmoduleiseasilyconfiguredusingaWindows®menu-styleroutine;theconfigurationroutinerequirestheBanner-suppliedHRMAsoftwareandaPC-compatiblecomputer(running Windows® XP, Vista, or 7)AserialdataconnectionismadebetweenthecomputerandtheDB9connectoronthecontrolmodule.
5.1 Communications Setup
Afterinstallingthesoftware,attachtheserialcommunicationcablebetweenthecontrolmoduleandthePC.(NOTE:IfanRS-232interfaceisused,onlyonecontrolmoduleisallowedonthelineatanyonetime.)Theminimumconnectionstothecontrolmodule’sDB-9connectorareshowninFigure3-8.
LaunchtheHigh-ResolutionMINI-ARRAYprogramandconfiguretheserialcommunicationsportofthePC.SelecttheOptionsmenufromtheHigh-ResolutionMINI-ARRAYmainmenu(seeFigure5-1).TheprogramsupportsserialcommunicationviatheCOM1-COM20.portofthecomputer.Highlightthedesiredserialporttoselectit(a“bullet”willappearnexttotheselectedoption),thenselectSave Settings on Exittostoretheserialportselection,ifitisnotalreadyON(a“bullet”willappearnexttotheoption,ifitisON).
Parityisselectedherealso:Even,OddorNone.
5.1.1 Ping Routine
ThePingroutinemustbeperformedduringSystemconfiguration,andbeforeanyDiagnostic,Alignment,orEditroutine.Theroutinepollsallcontrolmodulesonthecommunicationsline(one,inthecaseofthestandardRS-232line,orupto15modules,onanRS-485circuit).Itthenisusedtoselectanindividualcontrolmoduleforconfigurationoralignment.
Ifneeded,applypowertotheSystemcontrolmoduleandallowtheSystemtocompleteitspower-uproutine.PressF5oraccesstheMINI-ARRAYmenuandselectPingtoperformthePingroutine.AllconnectedcontrolmoduleswillthenidentifythemselveswithanIDvalueandbaudrate;theroutinetakesapproximately15to20seconds.AfterthePingisperformed,allvalidcontrolmoduleIDvalueswillappearinachartonthescreen,undertheirappropriatebaudrates(seeFigure5-3).Controlmodulesareidentifiedinthechartas‘X.’PointtoavalidIDwiththemousepointerandclicktoselectacontrolmodule.SystemDiagnostics,Alignment,orEditroutinesmaynowbeperformedfortheselectedcontrolmodule.
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5.1.2 Factory Settings
Ofthe15availablecontrolmoduleIDvalues(‘A’through‘O’),thefactorysoftwaresettingisA.Selectablecommunicationbaudratesare9600,19200,and38400;thefactorysettingis9600.Seesection5.3.1forinformationonchangingthesesettings.
5.2 System Alignment
Theemitter/receiverpairshaveawidefieldofviewandareeasytoalign.Therecommendeddistancebetweentheemitterandreceiverrangesfrom15"to72".(Shortersensorseparationcanbeachieved;pleaseconsultfactoryfordetails.)TheAlignmentprocessshouldbeperformedatSysteminstallationandrepeatedeverytimeoneorbothofthesensorsismoved.AlignmentoftheSystemcanbespecifiedautomaticallyusingeithertheAlignmentroutineoftheconfigurationsoftwareortheAlignmentswitchonthecontrolmodule’sfrontpanel.
TheSystemalsomaybealignedremotely,usingpins14and15ontheterminalblock.Apply10to30Vdcpowertothepins(seepage14)toapproximatethepush-buttonprocedure.(Forexample,applyinputsignalfor3secondstoaccessAlignmentmode.)
Makesurethesensorshavebeenwiredasshowninsection3.3.Applypowertothecontrolmoduleviaterminals#1and#2(16to30Vdc).TheDiagnosticsIndicatorwillshowthesensorsgoingthoughapower-uptest:firstthereceiver,thentheemitter.AfterthesensorshavebeentestedandtheSystemisreadyforservice,theDiagnosticsIndicatorwillshow‘—’or‘—.’;seeFigure5-4.
5.2.1 Push-button Alignment Routine
Atinstallationorwhenevertheemitterand/orreceiverismoved,theSystemshouldbere-aligned.PresstheAlignmentswitchonthecontrolmodulefrontpanelfor3seconds,afterwhichtimetheletter‘A’willappearontheDiagnosticsIndicator;theSystemis“learningaclearcondition.”Rotatethesensorsasrequired(butdonotchangethedistancebetweenthem).WhenthegreenAlignmentLEDisdisplayedonthecontrolmoduleandreceiver,thesensorsareadequatelyaligned.ToleaveAlignmentmode,againpresstheAlignmentswitchfor3seconds.
Duringthealignmentprocedure,thesystempollseachreceiverchanneltomeasureexcessgainandperformsacoarsegainadjustment.Whenthesystemexitsthealignmentprocedure,eachchannel’ssignalstrengthisstoredinnon-volatilememory.Thesystemisnowreadyforoperationanddoesnotrequirere-alignmentunlesstheemitterorreceiverismoved.
Figure 5-4. Diagnostics Indicator showing a clear condition
HIGH RESOLUTION MINI-ARRAY CONTROLLER
ALIGNMENTSWITCH
POWER
POWER
DIAGNOSTICSINDICATOR
2 - TX3 - RX5 - COM
RS-232
MAHCN-1
OUTP
UT
ALAR
M
GATE
ALIG
N
1
+ –
+ –
16-30V dc1A MAX
10-30VDCGATE
30V150mA MAXEMTR RCVR
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
NC NC NC+12V COM DRN T/R T/R
BR BU BK WHOUTPUT#1
TX TX
30V(MAX)150mA MAX
ALARM
+ –10-30VDC
ALIGN
RS-485
HIGH RESOLUTION MINI-ARRAY CONTROLLER
ALIGNMENTSWITCH
POWER
POWER
DIAGNOSTICSINDICATOR
2 - TX3 - RX5 - COM
RS-232
MAHCN-1
OUTP
UT
ALAR
M
GATE
ALIG
N
1
+ –
+ –
16-30V dc1A MAX
10-30VDCGATE
30V150mA MAXEMTR RCVR
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
NC NC NC+12V COM DRN T/R T/R
BR BU BK WHOUTPUT#1
TX TX
30V(MAX)150mA MAX
ALARM
+ –10-30VDC
ALIGN
RS-485
DenotesBlanking
With Blanking OFF
With Blanking ON
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P/N64118rev.B
5.2.2 Software Alignment Routine
ThegreenLEDindicatoronthereceiverandalsoonthecontrolmodulecontinuouslydisplaysAlignmentstatus.Whenallunblankedbeamsareclear,thegreenAlignmentindicatorswillbeON.Tobetterunderstandblocked,clearandblankedbeams,launchtheAlignmentroutine(pressF8orselectAlignmentundertheMINI-ARRAYmenu).Thescreenwillshowthestateofallofthebeamchannels,groupedintosetsof16.
KeyinformationprovidedontheAlignmentscreenisthesensorsize,plusthenumberofbeamsblocked,made,andblanked.Thesensorsizeisgiventhetitleof“total”;thisreferstothetotalnumberofbeamchannelsinthearray.Thenumberofbeamsblockedisarunningtotalofblockedbeams,excludinganyblankedbeams.The“made”valueisacountofunblockedbeams.The“blankedvalue”isacountofthenumberofbeamchannelsthatareblanked(channelsthatareignoredformeasurementmodeapplications;seesection5.2.3).
TheAlignmentscreenprovidesthefollowingfunctions:Start,Stop,Step,ClearBlankingFields,RestoreControlmoduleSettings,AutoBlanking,AbortAutoBlanking,SavetoFile,ReadFromFile,Cancel,OK,andEdit.Toaccessanyofthesesub-routines,firstpressStop,thentheselectedoption.
Startcommandcausesthecontrolmoduletocontinuouslyscanandreport“AllChannelData.”Thisdataisusedtoupdatethestateofeachbeamchannel.
Stopcommandcausesthecontrolmoduletostopscanning.
Stepcommandproducesonescanandthenstopsuntilanothercommandisissued.
Clear Blanking Fieldscommandisaquickwaytoremoveblankingspecifications.
Restore Control Module SettingswillrecalltheblankingspecificationsineffectpriortoAlignment/Blankingbeingentered.
Auto Blankingcommandisusedtoscananddeterminewhichbeamsareblocked;blockedbeamsautomaticallybecomeblankedbeams.TheAutoBlankingvaluescanthenbeAcceptedorAborted.
Editisusedtocontroltheblankingspecificationsofanychannelmanually.Thisisusefulforaddinganynumberofblankedbeamchannelsaboveand/orbelowablankedobjecttoallowforvibrationorothermovementoftheobjecttobeignored.
BlankingspecificationscanbesavedandreadfromacomputerfileusingtheSave To FileandRead From Filecommands.
Figure 5-5. Alignment screen
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5.2.3 Blanking
Ifamachinefixtureorotherequipmentwillcontinuouslyblockoneormorebeams,theaffectedbeamchannelsmaybeblanked.TheBlankingoptioncausesthecontrolmoduletoignorethestatusofblankedbeamsformeasurementmodecalculations.Forexample,ifamachinefixtureblocksoneormorebeamsduringSystemoperation,theoutputdatawillbeincorrect;ifbeamsblockedbythefixtureareblanked,theoutputdatawillbecorrect.Blankingmaybeconfiguredusingthepush-buttonAlignmentswitchonthecontrolmodule,orbyusingthesystemsoftwareandacomputer.
Push-Button Blanking Setup Routine To specify blanking using the control module’s Alignment switch,(seeFigure5.4)positiontheobjectorparttobeignoredinthepathofthebeamsbeforebeginningtheAlignmentroutine.PresstheAlignmentswitchfor3seconds;theDiagnosticsIndicatorwillshowtheletter‘A’.PresstheAlignmentswitchagain,butthistimeonlymomentarily(about0.5secondsmax.).TheDiagnosticsIndicatorwillshowtheletter‘b’toindicateitisreadyto“learn”theblankingpattern.Again,momentarilypresstheAlignmentswitchtosettheblankingfields.Boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshow‘A.’(theperiodfollowingthe‘A’indicatesthatblankingisinuse).Thebeamsblockedduringtheroutinearenowblanked.ToreturntoRunmode,againpresstheAlignmentswitchfor3seconds.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing‘—.’(seeFigure5-4).
System Software Blanking Setup Routine To specify blanking using the System software,theprocedureissimilar.Positiontheobjecttobeblankedinthepathofthebeams(thiscanbedoneatanytimebeforebeginningtheblankingroutine).PerformthePingroutinetoselectthepropercontrolmodule,thenpressF8orselecttheAlignmentoptionfromtheMINI-ARRAYmenu.Fromthescreenmenu(Figure5-6),selectStop;theDiagnosticsIndicatoronthecontrolmodulewillshowtheletter‘A’.SelectAuto Blanking (Figure5.7);theDiagnosticsIndicatorwillshowtheletter‘b’.SelectAccept Auto Blanking;boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshow‘A.’(theperiodfollowingthe‘A’indicatesthatblankingisinuse).Thebeamsblockedduringtheroutinearenowblankedandappearastheletter‘B’onthegridinsteadof‘0’;ifyouwishtoblankadditionalbeams,usethe‘Edit’keytomanuallysetadditionalblanking(seenextpage).ToleaveAlignmentmode,select‘OK’.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing‘—.’(seeFigure5-4).
Scanning Mode Limitations for Blanking:AllblankingfeaturesareavailablewithContinuousScanmode.Forsingle-anddouble-edgescan,blankingislimitedtofourblankingfields.Otherblankingfeaturesareignored.
Figure 5-6. Alignment screen, showing beams #1-11 blocked
Figure 5-7. Alignment screen, showing beams #1-11 blanked
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To accommodate parts or components that will move through the array,blankingmaybemanuallyadjustedforoneormoreindividualbeamchannels.AfterusingtheSystemsoftwaretospecifyblanking,select‘Edit’fromtheAlignmentscreen;theDiagnosticsIndicatorwillcontinuetoshowtheletter‘b’andagridwillappearonthecomputerscreen(Figure5-8).Thebeamsarenumberedfromthesensors’cabledends,withthebeamclosesttothecablebeingbeam#1.Tosettheblankingfields,‘click’eachgridboxrepresentingabeamyouwishtoblank.
Clickingagainonablankedbeamchannelwillremovetheblankingspecification.Rowsofchannelscanbeselectedorclearedoftheblankingspecificationbyplacingthecursordirectlytotheleftoftherowtobeselectedandclickingthemouse;therowshouldbehighlighted.SelecttheBlank Selected(toaccepttheblankingstatus)orClear Selected(torejecttheblankingstatus)option.ToleaveAlignmentmode,select‘OK’.Boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshow‘A.’.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing‘—.’(seeFigure5-4).
Figure 5-8. Edit channel blank state screen, showing beam #22 and beams #35-42 blanked; beams #65-80 are highlighted, ready to be selected for blanking
5.3 Programming Control Module Response
TheParameterSetupFile(PSF)Configurationroutine(seeFigure5-9)isusedtoconfigurethecontrolmoduleforaspecificapplication.AccessthePSFConfigurationscreen(afterperformingthePingroutinetoselectacontrolmodule,section5.1.1)byselectingEdit PSF (F4)fromtheMINI-ARRAYmenu.TheEditPSFprocessmayalsobeperformedwithnocontrolmoduleselected,toconfigureandsaveaPSFformultiplecontrolmodules.Insuchacase,somefieldsonthePSFConfigurationscreenwillnotbeaccessible.
Theprocessofconfiguringthecontrolmoduleinvolvesselectingamongoptionsforeachoftheparameterslistedinthissection,includingserialcommunication,controlmode,scanningmethod,scananalysismode,serialtransmission,andanalog/discreteoutputs.Theresultingcombinationofoptionscausesthecontrolmoduletoreactasrequiredfortheapplication,tochangesinthelightscreen.
TheconfigurationprocessproducesaParameterSetupFile(PSF).PSFfilesmaybesavedandretrievedascomputerfilesviatheFile Save PSFandFile Retrieve PSFcommands(seesection5.4.5).Onceconfigured,aPSFmaybesenttothecontrolmoduleviatheSend PSFcommand.Likewise,thePSFcurrentlyloadedintothecontrolmodulemaybedisplayedbyusingtheUpload PSFcommand.
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Figure 5-9. Use the PSF Configuration screen to program each control module individually
Serial TransmissionSpecifiesthetypeofdatatransmittedfromthecontrolmoduletoitshostaftereachscan.Measurement Mode Result:DatatransmittedwillreflecttheAnalysisModeselections.All Mode:Transmitsalldata.Max. Meas. Mode: Sendsonlythelargestmeasurementineachmeasuringevent,todecreasetransmissionsizeandspeedresponse.Choosetosendwhenthearrayisclearorsendatthehost’srequest.Transmission Type: ASCIIorBinary,definestheformatinwhichthedatawillbesent.Serial Options:SuppressClearDataorSuppressHeadertodecreasetransmissionsizeandspeedresponse.
Analysis (Measurement)Mode Selection
Choosethemeasurementoptionthatbesttellsyouthesizeand/orposition
ofobjectsastheyrelatetothearray.
Control Mode SelectionContinuous Mode:Thecontrol
moduleconstantlypollsthearrayforstatus.
Host Mode:Thecontrolmodulepollsthearrayforstatuswhenpromptedbyahostcontroller.
Gate Mode: Thecontrolmodulepollsthearrayforstatuswhenpromptedbyaninputfroma
Gatesensor.
Scanning MethodStraight scanpollseachbeam
sequentiallytodeterminethetargetobject’soverallsize.Thisisthemostaccurateandprecisemeasurement,butalsothemosttime-consuming.
Single Edge scanrequiresthetargetobjecttoblockbeam1(closesttothesensors’cabledends),thenconductsatime-savingbinarysearchto“hunt”forthetarget’s
overallheight(onevariableedge).
Double Edge scanconductsatime-savingsearchoftheentirearrayto“hunt”forthetarget’s
overallwidth(twovariableedges).
Set Point and Hysteresis SelectionAssignsthesetpointtodeterminewherewithinthearraytheoutput(s)willrespondandhysteresisvaluestosmoothoutputresponse.
Trigger/Trigger Channel NumberMaybeusedtotrigger(orgate)thescansequenceofanotherA-GAGE High-Resolution MINI-ARRAYcontroller;instraightscanningmode,itdefineswhenduringeachscandiscreteOutput#2willchangestate.
Scan #: (1-9)Analogoutputsareupdatedwithanaveragevalueofthedatareceivedduringtheselectednumberofscans;discreteoutputsrespondonlyifthereceiveddataisidenticalforalloftheselectednumberofconsecutivescans.
Analog and DiscreteOutput Assignment
Assignsananalysis(measurement)mode
toeachoutput.Alarm:CausesthecontrolmoduletoturnondiscreteOutput#2whenevertheSystemdetectsasensingerrororiftheopticalsignalbecomesmarginal.
Selected Controller Identifiesthespecificcontrolmodulebeing
configured.
Serial CommunicationChangestheidentificationandbaudrateofthecontrollerbeingconfigured.
Zero Value ZeroValueisusedtospecifytheanalogoutputwhenthemeasurementmodevalueiszero.TheusercanspecifyavalueofLAST,NULL,orSPAN.
LAST: Outputholdsthelastnon-zerovaluebeforethelightscreenbecameclear.
NULL: Providestheminimumvalue.
SPAN: Providesthemaximumvalue.
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P/N64118rev.B
5.3.1 Selected Controller and Serial Communication
TheSelectedControllerboxdisplaysinformationaboutthecontrolmodulebeingconfigured.TwoofthesesettingsmaybechangedintheSerialCommunicationbox.ThesettingsselectedanddisplayedintheseboxesarethoseusedtoidentifythecontrolmoduleduringthePingroutine(section5.1.1).
Controller ID(assignedaletter,‘A’through‘O’)isusedtoidentifyeachindividualcontrolmodulewhenmultiplediscrete-outputcontrolmodules(upto15)areconnectedononeEIA-485“partyline.”NOTE:AnalogoutputcontrolmodulesdonotofferRS-485communication;chooseanyIDletter(‘A’through‘O’)whenprogrammingananalog-outputcontrolmodule.
Baud Rateisthedatacommunicationratebetweenthecontrolmoduleandthecomputerusedforconfigurationandalsotheprocesscontroller.Choosefromthreevalues:9600, 19200,and38400.
Parity: SelectOdd,Even,orNone.AllcontrollersononeEIA-485partylineshouldhavethesameparitysettings.
5.3.2 Control Mode Selection
Thecontrolmodedeterminesthemethodusedtocontrolscanningofthelightscreenarray(seeFigure5-11).Choosefromthreemaincontrolmodes:
• ContinuousScanmode,• SerialHostCommandmode,and• Gatemode(whichitselfhasfouroptions)
In Continuous Scan Mode,thecontrolmodulebeginsanewscanassoonasitupdatestheoutputsfromthepreviousscan.Thisisthefastestscancontrolmethod;itisusedinmostanalogoutputapplicationsandwhenevercontinuousupdatingoftheoutputsisacceptable.
Host ModeallowsthecontrolmoduletocommunicatewithahostcomputerorcontrolmoduleviaRS-232(allmodels)orRS-485(discrete-outputmodelsonly)serialprotocol.ThehostdirectsthecontrolmoduletoscanondemandandreceivestheoutputdatafromthecontrolmoduleinbinaryorASCIIform.Baudratesof9600,19200,and38400areselectableintheSerialcommunicationsmenu(section5.3.1).(SeeAppendixAformoreinformationonHostmodedataformat.)
Gate ModeactivatesanopticallyisolatedexternalGateinputbetweenterminals12(+)and13(-)ofthecontrolmodule.TheGateinputhasimpedanceof7.5kΩandacceptsa10to30Vdcsignal.AdcdevicesuchasaphotoelectricsensororopticalencodertypicallysuppliestheGateinput.Gateinputsignalsmustbegreaterthan150microsecondsinduration;thetimebetweensuccessiveGateinputsmustbegreaterthantheminimumscantimeforthelightscreenarray(seesection5.3.3forscantimeinformation).
Gatemodehasfouroptions:• Gate ON: thecontrolmodulewillscanaslongasthegateisactive.• Gate OFF: thecontrolmodulewillscanwheneverthegateisnotactive.• Gate ON/OFF: thecontrolmodulewillscanonceforeachgatetransitionfromONtoOFF.• Gate OFF/ON:thecontrolmodulewillscanonceforeachgatetransitionfromOFFtoON.
Figure 5-11. Control Mode selections (PSF Configuration screen)
Figure 5-10. Selected Controller and Serial Communication selections (PSF Configuration screen)
Control Module Configuration
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5.3.3 Scanning Method
Thecontrolmodulemaybeconfiguredforoneofthreescanningmethods(Figure5-12):• Straightscan• Single-Edgescan• Double-Edgescan
Straight Scanisthedefaultmodeinwhichallbeamsarescannedinsequencefromthebottomend(cableend)tothetopendofthearray.Thisscanningmethodrequiresthelongestscantimesandprovidesthesmallestobjectdetectionsize(2.5mm,0.1"diameter).
Single-Edge Scanisusedtomeasuretheheightofasingleobject.Agoodapplicationforthisscanningmethodisboxheightmeasurement.ForSingle-EdgeScan,theSystemalwaysactivatesthefirstbeamchannel(nearestthecableend,or“bottom”).Ifthefirstbeamisblocked,thesensorwillperformabinarysearchtohuntforthelastbeamblocked.Single-EdgeScanworksasfollows:
1. Thereceiverscansonlythebottombeamuntilthatbeamisblocked.
2. Whenthebottombeamisblocked,thesensorlookstoseewhetherthemiddlebeamisblockedormade(unblocked).
3. Ifthemiddlebeamismade(unblocked),thesensorchecksthebottomquarterbeam;ifthemiddlebeamisblocked,thesensorchecksthetopquarterbeam.(Thisiscalledabinarysearch;seeFigure5-13.)
4. Thisroutinecontinuesto“narrowthefield”untiltheedgeisfound.
Notethatthereceiveralwayschecksthebottombeamfirst,andonlyifthatbeamisblockeddoesthebinarysearchcontinue.Therefore,Single-EdgeScanwillnotworkininstanceswhereanitemthatdoesnotblockthefirstbeamistobemeasured.Single-EdgeScanisalsoineffectiveiftheobjectdoesnotpresentacontinuousblockedpattern.Inotherwords,Single-EdgeScanisusedforsingle,solidobjectsthatblockthefirstbeam.
Figure 5-12. Scanning Method selections (PSF Configuration screen)
DIAGNOSTICS
Error No.
Error Type
Error No.
Error Type
—�
System OK
4
Emitter Error
1
Align / blank
5
Serial Comm
2
Output Short
6
EEPROM
3
E / R Mismatch
7
CPU Error
4
Receiver Error
8
Null / Span
1POWER
2 - TX
3 - RX
5 - COM
ALIGNMENT
SWITCH
DIAGNOSTICS
INDICATOR
RS-232
MAHCN-1
HIGH RESOLUTION MINI-ARRAY CONTROLLER
23
45
67
89
1011
1213
1415
1617
1819
20
1
+
NC
NC10-30Vdc
GATE
NC
TXTX
+12V
BR
EMTR
RCVR
BU
BK
5 Wires
WH
30V
150mA MAX
OUTPUT#1
COMDRN
T/RT/R
16-30V dc
1A MAX
POWER2
34
56
78
910
1112
1314
1516
1718
1920
OUTP
UTAL
ARM
GATE AL
IGN
–�
+–�
F1
30V(MAX)
150mA MAX
ALARM
10-30Vdc
ALIGN
RS-485+
–�
High-ResolutionEmitter
MAHCN-1Control Module
High-ResolutionReceiver
Beam #1 of 64Blocked
Beam #48Clear
Beam #32Blocked
Beam #44Clear
Beam #40Blocked
Beam #42Blocked
Beam #43Blocked
Step #2Step #1 Step #3
Step #4 Step #5 Step #6 Step #7
Figure 5-13. Finding an edge using a binary search
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Double-Edge Scanisusedtodetecttwoedgesofasingleobject,forexample,boxwidthmeasurements.Double-EdgeScanrequirestheselectionofastepsize:2,4,8,16or32beams.Thesensorusesthestepsto“skip”overbeams.Double-EdgeScanworksasfollows:
1. Thesensoractivatesbeam#1(thebeamclosesttothesensorcableend).
2. Thesensoractivatesthenextbeam,determinedbythestepsize.(Forexample,ifthestepsizeis2,beam#3isnext;ifthestepsizeis8,beam#9isnext.)
3. Aslongastheactivatedbeamisunblocked(or“made”),thesensorwillcontinuethesteppingroutineuntilablockedbeamisfound.
4. Whenablockedbeamisfound,abinarysearchisconductedtofindtheobject’s“bottomedge.”
5. Whenthebottomedgeisfound,thesensorbegins“stepping”againthroughthearrayuntilthesensorfindsthenextunblockedbeam.
6. Abinarysearchisagainperformedtofindthesecondedge.
Notethatthisscanningmethodsacrificesobjectdetectionsizeforspeed.SimilartoSingle-EdgeScan,Double-EdgeScanhassomerestrictions:theobjectshouldprovideasolidobstruction;thesizeoftheobjectwilldeterminethemaximumstepsize(Figure5-14).
Sensorresponsetimeisafunctionofsensorlengthandscanningmethod.TypicalscantimesareshowninFigure5-15.
Step Size
Number of Beams
MinimumObjectDetectionSize
5mm(0.2")
10mm(0.4")
20mm(0.8")
40mm(1.6")
80mm(3.2")
Maximum Scan Times (in milliseconds)
Array Length
Straight Scan
Single- Edge Scan
Double-Edge ScanStep
2 BeamsStep
4 BeamsStep
8 BeamsStep
16 BeamsStep
32 Beams163 mm(6.4") 5.8 1.8 3.4 2.7 2.5 2.6
325 mm(12.8") 10.6 1.9 8.1 5.1 3.6 3.0 2.7
488 mm(19.2") 15.0 2.1 11.5 6.8 4.5 3.4 3.0
650 mm(25.6") 20.1 2.1 14.9 8.5 5.3 3.9 3.2
812 mm(32.0") 24.9 2.1 18.3 10.1 6.1 4.2 3.5
975 mm(38.4") 30.0 2.1 21.7 11.8 7.0 4.7 3.6
1138 mm(44.8") 34.5 2.1 25.0 13.5 7.9 5.1 3.8
1300 mm(51.2") 39.3 2.1 28.4 15.2 8.7 5.5 4.1
1626 mm(64.0") 48.0 2.3 35.1 18.6 10.4 6.4 4.5
4.8
1788 mm(70.4") 53.6 2.3 38.5 20.3 11.2 6.8 4.7
Figure 5-14. The effect of step size on minimum object detection size
Figure 5-15. The effect of sensor length and scanning method on scan time (typical)
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NOTE:Scantimesareexclusiveofserialcommunicationtransmissiontimes.
1463 mm(57.6") 44.0 2.2 31.8 16.9 9.5 5.9 4.3
1951 mm(76.8") 58.4 2.3 41.9 21.9 12.1 7.2 4.9
2 4 8 16 32
P/N64118rev.B
Control Module Configuration
26
5.3.4 Scan Analysis Mode Selection
Thecontrolmodulemaybeprogrammed,ifdesired,foranyoneortwoofsevenScanAnalysis(measurement)Modes.Eachselectedmodemaybeassignedindividuallytoanoutput(seesection5.3.5or5.3.6).Thebeamsinthearrayarenumberedinsequence,withbeam#1locatedatthecabledendoftheemitterandthereceiver.
“Beam Location” Modes• First Beam Blocked (FBB): ThecontrolmoduleidentifiesthelocationoftheFirstBeamBlocked.
• First Beam Made (FBM):ThecontrolmoduleidentifiesthelocationoftheFirstBeamMade(unblocked).
• Last Beam Blocked (LBB):ThecontrolmoduleidentifiesthelocationoftheLastBeamBlocked.
• Last Beam Made (LBM):ThecontrolmoduleidentifiesthelocationoftheLastBeamMade(unblocked).
• Middle Beam Blocked (MBB):ThecontrolmoduleidentifiesthelocationoftheMiddleBeamBlocked,midwaybetweenthefirstandlastbeamsblocked.
“Beam Total” Modes• Total Beams Blocked (TBB): Thecontrolmoduletotalsthenumberofblockedbeams.
• Total Beams Made (TBM): Thecontrolmoduletotalsthenumberofmade(unblocked)beams.
• Contiguous Beams Blocked (CBB):Thecontrolmoduleidentifiesthelargestnumberofconsecutivelyblockedbeams.
• Contiguous Beams Made (CBM):Thecontrolmoduleidentifiesthelargestnumberofconsecutivelymadebeams.
• Transitions (TRN):Thecontrolmodulecountschangesfromblockedtoclearandcleartoblocked.Forinstance,ifbeams6-34areblocked,thenthereisaclear-to-blockedtransitionfrombeam5tobeam6,andablocked-to-cleartransitionfrombeam34tobeam35.Transitionmodecanbeusedtocountobjectswithinthearray.
TheAnalysisMode(s)programmedmaybeassignedtoanyoneoftheavailableoutputs(seeFigure5-18).EachoutputcanbesetforMEAS1, MEAS2, MEAS1 InvertedorMEAS2 Inverted.
5.3.5 Analog Output Configuration (Analysis Mode Assignment)
Analogoutputs#1and#2mayeachbeassignedtooneoftheanalysismodesdescribedinsection5.3.4.WhentheselectedScanAnalysisModeinvolvesfirstorlastbeamblockedormade(unblocked),theassignedoutputwillvaryinproportiontothebeamnumberidentifiedduringascan.WhentheScanAnalysisModeinvolvestotalbeamsblockedormade,thatassignedoutputwillvaryinproportiontothetotalbeamscountedduringascan.
Notethatthepull-downmenususedforassignmentoftheScanAnalysisModestotheanalogoutputsincludetwo“Inverted”selections.WheneitherMEAS1 InvertedorMEAS2 Invertedisselected,thatanalogoutputwilldecreaseasthemeasurementmodevalueincreases.Aninvertedoutputwillbeatfullscale(Spanvalue)whenthescananalysisvalueiszero;andatmaximumscananalysisvalue,theoutputwillbeattheNullvalue.
Figure 5-18. Assigning an Analysis Mode to each Analog Output
(PSF Configuration screen)
Figure 5-17. Examples of MINI-ARRAY scan analysis modes
Figure 5-16. Scan Analysis Mode Selection (PSF Configuration screen)
Last Beam Made (LBM)First Beam Made (FBM)
Receiver
Emitter
8
16
24
32
40
48
Last Beam Blocked (LBB)First Beam Blocked (FBB)
Receiver
Emitter
8
16
24
32
40
48
Total Beams Made (TBM)Total Beams Blocked (TBB)
Receiver
Emitter
8
16
24
32
40
48
InLastBeamBlockedmode,lastbeamis#43of48
InFirstBeamBlockedmode,firstbeamis#15of48
InLastBeamMademode,lastbeamis#37of48
InFirstBeamMademode,firstbeamis#26of48
InTotalBeamsMademode,34of48possiblebeamsaremade
InTotalBeamsBlockedmode,14of48possiblebeamsareblocked
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TheNullandSpanrangesmaybeadjustedasfollows:
Toreadthenewvaluesonthemeter,clickonNullorSpan Update.ClickontheOKbuttontosavethenewsettingsandreturntheprogramtothePSFConfigurationscreen.ClickingontheCancelbuttonreturnstheprogramtothepreviouslysavednullandspansettings.
NOTE:NullandSpanarefactorysettospecifiedvaluesandusuallyrequirenochanges.
Scan #Providesawaytosmoothoutputresponseandavoidunstableanalogoutputconditions.Themenuallowsselectionoffrom1to9scans(seeFigure5-20).Foranalogoutputs,ifscan#issetatmorethan1,thescananalysisvalueisaveragedforalloftheselectednumberofconsecutivescans,preventingdipsandspikesintheoutputs.
Fortotalbeamvalues(TBBandTBManalysismodes),programmingofblankedbeams(section5.2.3)willaffecttheproportionalanalogoutputs.Blankedbeamsareignoredbothinthenumberofblockedormadebeamsandthetotalnumberofbeams.Forexample,ifa64-beamarrayhas20blankedbeamsand22oftheremaining44beamsareblocked,theoutputvalueswillbeatmid-range.
5.3.6 Zero Value
Zerovalueisusedtospecifytheanalogoutputwhenthemeasurementmodevalueiszero.TheusercanselectananalogoutputofLAST,NULL,orSPAN.
LAST: Outputholdsthelastnon-zerovaluebeforethelightscreenbecameclear.NULL: ProvidestheminimumvalueSPAN: Providesthemaximumvalue.
TheNull/SpanConfigurationscreen(Figure5-19),maybeusedtoadjustthezeroandfullscalereadingforeitheranalogoutput.TodisplaytheNull/SpanConfigurationscreen,clickontheNull/SpanbuttonatthebottomofthePSFConfigurationscreen(Figure5-9).Eachoutputisindependentandmustbeadjustedseparately.AdjusttheNullandSpanvalueseitherbymovingtheslidebars,orbyenteringanewvalueonthekeyboard.
To Measure:Analog Voltage Output:Connectthevoltmeterbetweenterminals10or16(+)and17(–).
Analog Current Output:Connecttheammeterbetweenterminals10or16(–)and1(+).
Analog Output Type
Null SpanMinimum Maximum Minimum Maximum
Voltage 10mV 2.3V 4.8V 10.1V
Current 3.9mA 7.8mA 11.9mA 20.2mA
Figure 5-19. Null/Span Configuration screen
Figure 5-20. Scan # (PSF Configuration screen)
Figure 5-21. Zero Value (PSF Configuration screen)
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NOTE:WhenintheNull/Spanscreen,thecontrollerwillhaveadiagnosticcodeof8.
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5.3.7 Discrete Output Configuration (Analysis Mode Assignment)
Discreteoutputs#1and#2(“Alarm”)mayeachbeindividuallyassignedtooneoftheScanAnalysisModesprogrammedinsection5.3.4(seeFigures5-16and5-22).
NexttoeachdiscreteoutputassignmentmenuareLowandHigh Set Pointboxes.Thenumberineachboxidentifiesabeaminthearray(beam#1beingclosesttothecabledendoftheemitterandthereceiver).TheLowandHighSetPointsmaybechangedbyclickingonaboxandenteringanewnumber.
WhentheselectedScanAnalysisModeinvolvesfirstorlastbeamblockedormade(unblocked),theassignedoutputwillenergizewhenthebeamidentifiedduringascanfallswithintherangeofthesetpoints.WhentheScanAnalysisModeinvolvestotalbeamsblockedormade,thatassignedoutputwillenergizewhenthevalueoftotalbeamscountedduringascanfallswithintherangeofthesetpoints.
Notethatthepull-downmenususedforassignmentoftheScanAnalysisModestothediscreteoutputsincludetwo“Inverted”selections.WheneitherMEAS1 InvertedorMEAS2 Invertedisselected,thatdiscreteoutputwillde-energize(turnOFF)wheneverascananalysisvaluefallswithintherangeofthesetpoints.
Hysteresisvaluesforeachendofthesetpointrangemayalsobeset(Figure5-22).Hysteresisdeterminestheamountofchangethatmustoccurateachsetpoint(HighandLow)tocausetheassociatedoutputtochangestate.Hysteresispreventsunstableoutputconditionswhenthescananalysisvalueexactlymatchesoneofthesetpoints.ThedefaulthysteresissettingisonebeamlessthantheLowSetPointandonebeammorethantheHighSetPoint.
Scan #Providesanotherway,inadditiontohysteresissettings,tosmoothoutputresponse.Outputsareupdatedonlyaftertheselectednumberofidentical(withinthehysteresislimits)scans.Themenuallowsselectionoffrom1to9scans.Fordiscreteoutputs,thescananalysisvaluemuststayeitherinsideoroutsidethehysteresislimitsforalloftheselectednumberofconsecutivescans,inorderfortheoutputtorespond.SeeFigure5-23.
Alarm and TriggerDiscreteoutput#2(only)hastwoadditionaloptions:AlarmandTrigger.
Alarm:Output#2energizeswhenevertheSystemdetectsasensorerror(suchasadisconnectedcable)orwhenevertheexcessgainofoneormorebeamsbecomesmarginal.
Trigger: canbeusedtogateasecondcontrolmodulewhenContinuousScanMethodisalsoused.Whenthecontrolmoduleisinstraightscanningmode,Trigger ChannelNumberdefinesthebeamnumberduringascanatwhichthetriggeroutputwilloccur(Figure5-23).TheTriggeroutputisa100microsecond(0.0001sec.)pulse.Ifthecontrolmoduleissetforsingleordoubleedgescan,theTriggerpulsewillcomeattheendofthescan(Trigger Channel Numberwillbeignored).
Figure 5-23. Scan # (PSF Configuration Screen)
Figure 5-24. Trigger Channel
Figure 5-22. Assigning an Analysis Mode to each Discrete output (PSF Configuration screen). Alarm and Trigger output options are available only for Discrete Output #2.
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5.4 Serial Communication with a Host Controller
ThecontrolmodulecommunicateswithahostprocesscontrollerviaRS-232orRS-485protocolandatthebaudratespecifiedintheSerialCommunicationsbox(section5.3.1).TheSystemprovidesanumberofdatatransmissionoptions.
5.4.1 Serial Data Transmission
TheserialtransmissionportionofthePSFConfigurationscreenactivatestheserialport(s),specifiesthedataformat,andprovidesdatasuppressionoptions.Thesesettingsarerequiredtoallowacontrolmoduletocommunicatewithahostcomputerorprocesscontroller.IfNo Serial Communicationisselected(thedefaultsetting),theserialport(s)willnottransmitsensingdata.
Measurement Mode Result: datatransmittedwillbethevaluesoutputfortheScanAnalysisModeselections.UptotwoScanAnalysisModeselectionscanbeactive.
ALL Mode: thestatusofeachbeaminthelightscreenarraywillbetransmittedforeach scan. InALLmode,blankedchannelsaretransmittedasunblocked(orclear)beams.
Max Meas Mode: thecontrolmodulerecordsthemaximummeasurementvalueregisteredwhilethelightscreenisblocked.Thatdatamaybetransmittedtothehosteitherwhenthearrayisclearattheendofthesensingevent(selectSend On Clear),orwhenpromptedbythehost(selectSend On Request).Thismodereducestheamountofserialdatasent.
5.4.2 Transmission Type
Transmissiontypedefinestheformatinwhichdataissent.TheASCIIoptioncausesthecontrolmoduletosenddatainthreeASCII-codedbytes.TheBinaryoptioncausesdatatobesentinbinaryformat,reducingtheamountofdatapermeasurementmodefromthreebytestotwo.Formoreinformationonthedataformats,refertoAppendixA.
Figure 5-25. Serial Data Transmission options (PSF Configuration screen)
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5.4.3 Serial Options
TheSerialOptionsboxprovidestwooptions:Suppress Clear DataandSuppress Header.
Suppress Clear Dataprovidesonemethodtoreducetheamountofdatabeingtransmittedbythecontrolmodule,accomplishedbynotsendingdatawhennoobjectisdetected.Thecontrolmoduletransmitsserialdataonlywhenoneormoreunblankedbeamsofthelightscreenarrayareblocked.Whenthearraygoesfromblockedtoclear,dataissentoneadditionaltime,indicatingtheclearcondition.
Suppress Headerisusedtopreventtransmissionofthethree-byteidentificationstring(“headerstring”)associatedwitheitherASCIIorBinarydataformats.Theheaderstringconsistsoftwobytesatthestartofthedata,andaterminationbytetomarktheendoftheserialtransmission.SeeAppendixAformoreinformationonserialdataformats.
5.5 Transfer of PSF to the Control Module
AftermakingalloftheselectionsinthePSFConfigurationscreen,thePSFmaybesenttothecontrolmodulebyclickingtheSend PSFbutton(seeFigure5-26).ThiscommandloadsthePSFintothenon-volatilememoryofthecontrolmodule,andautomaticallyoverwritesthecurrentPSF.TheprogramwillconfirmthatthePSFwasaccepted,orwillnotifytheuserofchangesrequiredtothePSF.
TocheckthevaluesofthePSFcurrentlyloadedintothecontrolmodule,selectUpload PSF.ThecurrentPSFwillbedisplayedonthePSFConfigurationscreen.
Figure 5-26. PSF Output options (PSF Configuration screen)
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5.5.1 Saving and Recalling PSF Files
ToplacethedisplayedPSFintoafilethatcanberetrievedatanytime,selectFile Save PSF (Figure5-26).WhenaskedifyouwanttosavethePSFtoafile,selectYes.AsubscreentitledFileSavewillappear(Figure5-27).Overtype‘*.psf’intheFileNameentryboxwiththenameofthefiletobestored(upto8characters),plusthe.psfextension;thenselectOK(orpressEnter).ThePSFwillbestoredontheselecteddrive(defaultis‘c:’)andtheprogramwillautomaticallyreturntothePSFConfigurationscreen.
ToretrieveafiledPSF,selectFile Retrieve PSF.TheFileBoxsubscreenwillappear(Figure5-28).SelectthedesiredPSFfromtheFileNamelistandselectOK(orpressEnter).TheselectedPSFwillloadtothePSFConfigurationscreen,anditcanthenbeloadedintothecontrollerusingtheSend PSFcommand.
5.5.2 PSF Output Analysis
ToviewactivityinthearrayinresponsetothecurrentlyloadedPSF,selectExecute (Figure5-26).TheMeasurementOutputscreenwillappear(Figure5-29);selectRun.Thetablewilldisplaythestatusfortheselectedmeasurementmode(s),includingthePresentvalueandtheHighandLowvaluesfortheRunperiod.
SelectStopto“freeze”thedata.SelectSteptoinitiateasinglescanofthearraytosimulatea“snapshot”ofwhatisviewedbythearrayattheinstantthatStepisselected.
UseoftheExecutecommandisespeciallybeneficialfortestingtheresponseofagatedsystem.RunsimulatestheContinuousScanningmode,andStepsimulatesagateinputcommand.
5.5.3 Quit and Exit
ToclosethePSFConfigurationscreen,selecteitherQuitorExit (Figure5-26).SelectingQuiterasestheEditPSFScreenandsendstheuserbacktotheMainWindow;thepresentPSFScreenvaluesarenotretained.TheExitcommandissimilartotheQuitcommand,excepttheuserwillbepromptedtosavetheconfigurationvaluestoaparametersetupfile(PSF).
Figure 5-27. FileSave subscreen of the PSF Configuration screen, accessed with the File Save PSF command
Figure 5-28. FileBox subscreen of the PSF Configuration screen, accessed with the File Retrieve PSF command
Figure 5-29. Measurement Output subscreen of the PSF Configuration screen, accessed with the Execute command
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6. System DiagnosticsSystemdiagnosticsmaybeperformedusingthestatusanddiagnosticsindicatorsonthecontrolmoduleandsensors,orbyusingtheDiagnosticssoftwareroutine,oracombinationofthetwo.
6.1 Diagnostics Indicators
NOTE:Statusindicatorsappearto“freeze”ifthecontrollerhasbeenconfiguredforGateorHostmode(Section5.3.2),andnosignalispresenttocauseascanupdate.
DIAGNOSTICSError No. Error Type/Action
– System is OK
A / b Align / blank• Status
1 Output Short• Checkoutputload&wiring
2E / R Mismatch• Systemmustusesamelengthemitterandreceiver
3Receiver Error• Checkreceivercable•Replacereceiver
4Emitter Error• Checkemittercable•Replaceemitter
5 Serial Comm• Checkserialcable
6EEPROM• ReconfigurePSF•Replacecontrolmodule• Reconfigureblanking
7 CPU Error• Replacecontrolmodule
8 Null / Span• Status
Figure 6-2. Key to System Diagnostics Indicator codes
Red OperationalLED
Green Alignment LED
Red Blocked LED
Yellow MarginalAlignment LED
High-ResolutionEmitter
High-ResolutionReceiverDIN-Rail-Mountable
Control Module
HIGH RESOLUTION MINI-ARRAY CONTROLLER
ALIGNMENTSWITCH
POWER
POWER
DIAGNOSTICSINDICATOR
2 - TX3 - RX5 - COM
RS-232
MAHCVP-1
OUTP
UT
ALAR
M
GATE
ALIG
N
1
+ –
+ –
16-30V dc1A MAX
10-30VDCGATE
D OUT 1 150mA MAX
0-10VOLTS25mA (MAX)
V OUT 1
EMTR RCVR
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1 +12V COM DRN T/R T/R
BR BU BK WH
TX TX+ –
10-30VDCALIGN
0-10VOLTS25mA (MAX)
V OUT 2+V
ALARM150mA MAX
+V
Diagnostics Indicator
Alignment Button
Red Discrete Output #1 LEDRed Alarm (Discrete Output #2) LED
Red Gate LEDGreen Align LED
RS-232 Port
Figure 6-1. A-GAGE High-Resolution MINI-ARRAY System diagnostics and status indicators
Bright,easy-to-seeLEDindicatorsonbothsensorsandonthefrontpanelofthecontrolmoduleprovideanongoingdisplayofthesystem’soperatingstatus.
Control Module:OUTPUT:(red)displaysthestatusofDiscreteOutput#1.
ALARM: (red)displaysthestatusofDiscreteOutput#2.Thisoutputmaybeassignedtoananalysismode,oritmaybeusedasaSystemDiagnosticsalarmorasaTriggeralarmtogateanotherA-GAGEHigh-ResolutionMINI-ARRAYSystem.
GATE:(red)displaysthestatusoftheGateinput.
ALIGN: (green)indicatesproperemitter/receiveralignmentandaclear,unblockedlightscreen.ThisindicatorisONwheneitherthegreenorboththegreenandyellowLEDsofthereceiverareON.
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Diagnostics Indicator: Thisbright,segmentedLEDdisplayonthecontrolmodulefrontpanelindicatesoneof10Systemstatusconditions,plusthepresenceorabsenceofblanking.(BlankingONcausesaperiodtoappearintheDiagnosticsIndicatorwindow,inadditiontotheSystem’sotherstatuscondition.)SeeFigure6-2forthekeytotheseerrortypesandstatusconditions;thischartisalsolocatedonthesideofthecontrolmodule.
Emitter: OPERATIONAL:(red)LEDindicatespowertotheemitterisON,andunitisoperational.
Receiver: BLOCKED: (red)LEDindicatessomeofthearraybeamsareblocked.
MARGINAL:(yellow)LEDindicatesthatarrayalignmentismarginal.
ALIGNMENT: (green)LEDindicatesthatarrayalignmentissatisfactory.
Toimprovealignment,adjustthepositionoftheemitterandreceiveruntilthegreenLEDlights,makingsurethatnounblankedbeamsareinterrupted.ThenuseoneofthemethodsinSection5.2torealignthesystem.
6.2 Diagnostics Routine
EmitterorreceiverproblemsmaybefurtherdiagnosedusingtheDiagnosticsroutineincludedwiththeMINI-ARRAYsoftware.LaunchtheprogrambyselectingDiagnosticsundertheMINI-ARRAYmenu(Figure5-2)orbypressingF2.
TheDiagnosticsscreen(Figure6-3)displaysthesizeofeachemitterandreceiver(expressedinthenumberof64-element“boards”itcontains)anditsfunctionalstatus(orstate).Ifanerrorhasoccurred,thespecificproblembeamchannelisidentified.Additionally,ifthereisaproblemwithanemitterorreceivercableconnection,a“No Response”messageisdisplayed.
TheDiagnosticsroutinealsodisplaysthepartnumberanddatecodeofthecontroller,informationthatmaybeusefuliffactory-assistedtroubleshootingbytelephoneisrequired.
Figure 6-3. Diagnostics screen, accessible from the MINI-ARRAY menu
P/N64118rev.B
Appendix A: Data Transmission
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Appendix A: Data Transmission
A.1 Host Mode Command String
Asdiscussedinsection5.3.2ofthismanual,thecontrolmodulehasthreecontrolmodeoptions:continuous,gate,andhost.Hostmoderequiresaserialtransmissionstringfromaseparatedevice,typicallyaPCorprocesscontroller.TheserialtransmissionmediumcanbeeitherRS-485orRS-232.
WhenHostcontrolmodeisselected,thehostprocesscontrollerinitiatesscansusingacommandstring.Thecommandstringisathree-bytemessage,consistingof:
•Controlbytewithdecimalvalue248,
•ControllerID(theidentificationofaspecificcontrolmoduleonthestring,indicatedbyoneof15ASCIIlettersAthroughO,andspecifiedinthePSF),and
•Scaninitiationbyte(ASCIIletterS).
Thecommandstringisfurtherdefinedasfollows:
/*the below C code will define an array called msg that will contain the Host Scan Command */ unsigned char msg[3]; /*declare three byte unsigned character array using C language */ msg[0]=248; /*control byte */ msg[1]=65; /*assume the controller ID is the letter A */ msg[2]=83; /*assume initiation byte which is the ASCII letter S */
Thehosttransmitsthisthree-bytemessageatthedefinedbaudrate.Theformatisonestartbit,onestopbit,evenparity,andeightdatabits.Whenthecontrolmodulereceivesthismessage,itinitiatesascan(assumingHostmodeisselected)andthenupdatesitsoutputsasrequired.ThecontrolmodulethenwaitsforthenextHostCommandmessagebeforeinitiatinganotherscan.
A.2 Serial Data Format and Header String
Theprogrammedmeasurementmodeormodesdeterminethetypeofinformationthatisseriallytransmitted.ForexampleifMeas1issetforFBBandMeas2issetforLBB,thenthedatatransmittedtothehostcontainsthevaluesofthefirstandlastbeamblocked.TheAllmeasurementmodeprovidesthestatusofallbeamstothehost.
Inadditiontomeasurementmodeinformation,thedatatransmissionalsocontainsatwo-bytestartstringandaterminationbyte.Thestartstringconsistsofafirstbytethatdoesnotchange,followedbythecontrollerID.Thefirstbytevalueisahex1Cor28decimal.Attheendofthestring,thecontrolmodulewillplaceaterminationbyte.TheterminationbyeistheASCIIcharacterforalinefeed(hexvalue0A).ThesethreebytescollectivelyarecalledtheSerialHeaderstring.
Figure A-1. Serial Transmission options (PSF Configuration screen)
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P/N64118rev.B
A.2.1 ASCII Format Data Transmission
TherearetwowaystouseASCIIformattorepresentdata.Theoneuseddependsuponwhichmeasurementmodesareselected.
For ALL measurement mode,eachdatabyteispresentedinaneight-bitASCIIformatthatconveysthestatusoffourconsecutivechannels(fourconsecutivebeams).Eachsubsequentbyteconveysthestatusofthenextfourchannels,untilthestatusofeverychannelisreported.TheallowabledatavaluesforAllmeasurementmodeareASCIInumbers0to9andASCIIlettersAtoF.Inthetable,a‘0’representsanunblockedbeamchannel,and‘1’representsablockedchannel.
Forexample,assumethata64-channelsystemhasbeenconfiguredfortheAllmeasurementSerialtransmissionoption.Channels1through4areblocked,asischannel63.Theserialstringstartswith0x1c,andtheID(assumean‘A’)followedby16ASCIIvaluesandterminatedwith0x0A.Thestringwouldappear:
0x1c, ‘A’, ‘F’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’4’, 0x0a
Thestringshowsthatbeams1through4areblocked,asisbeam63.Allotherbeamsareunblocked.Iftheuserhadrequestedsuppressionoftheheader,then0x1c,‘A’,andthe0x0awouldhavebeendeleted.
For transmitting Measurement mode data,usethreeASCIIbytestorepresenteachmeasurementmode.Forexample,ifMeas1isFBB,Meas2isLBB,themeasuredvaluesare6and120,andthecontrollerIDisB,thedatastringisasfollows:
0x1c ‘B’, ‘0’, ‘0’, ‘6’, ‘1’, ‘2’, ‘0’, 0x0a
AswithALLmode,theheaderandcleardatacouldbesuppressed.Forcleardatasuppression,thecontrolmodulesendsthestatusofaclearconditiononlyonthefirst“clear”scan.Afterthat,thecontrolmodulewillcontinuetoscanbutwillnottransmitdatauntilthesensorisagainblocked.
A.2.2 Binary Format Data Transmission
SimilartoASCIIformat,binaryformatmaybeusedtorepresentdataintwoways.OnemethodinvolvestheAllDatatransmissionmode;theother,Measurementmode.
For All Data transmission mode,thecontrolmodulerepresentsthestatusofeightconsecutivedatachannelsforeachbyte.Eachbitofeachbyteisdirectlyrelatedtothestatusofanindividualchannel.Thefirstdatabyterepresentschannels1through8;theseconddatabyterepresentschannels9through16.ThebitpatternforthefirstandseconddatabytesisasshowninFigureA-3.
Foreachbitposition,1representsablockedbeamand0representsanunblockedbeam.
Forexample,fora64-channelsystemwithbeams1-6blocked,beam43blockedandbeams62-64blocked,thedatatransmittedfromcontrolmodule‘A’isasfollows:
0x1c, ‘A’, 0xFC, 0x00, 0x00, 0x00, 0x00, 0x20, 0x00, 0x07, 0x0A
Thisstringwouldhavethestartbyte,controllerID,followedbytheeightdatabytesandterminatedwiththe0x0A.Theheaderbytesmaybesuppressedifnecessary.
Appendix A: Data Transmission
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Figure A-2. ASCII data values
Definitions for ASCII Data ValuesFortheALLmeasurementmode
Character Ch 4 Ch3 Ch2 Ch1
F 1 1 1 1
E 1 1 1 0
D 1 1 0 1
C 1 1 0 0
B 1 0 1 1
A 1 0 1 0
9 1 0 0 1
8 1 0 0 0
7 0 1 1 1
6 0 1 1 0
5 0 1 0 1
4 0 1 0 0
3 0 0 1 1
2 0 0 1 0
1 0 0 0 1
0 0 0 0 0
First Data Byte Second Data Byte
ChannelBit
Position ChannelBit
Position1 7 9 7
2 6 10 6
3 5 11 5
4 4 12 4
5 3 13 3
6 2 14 2
7 1 15 1
8 0 16 0
Figure A-3. Binary data values
P/N64118rev.B
Appendix A: Data Transmission
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For Measurement mode analysis,thebinaryformatusestwodatabytesforeachmeasurementmode.(Ifwehaveonemeasurementmode,thentherearetwodatabytes.Fortwomeasurementmodes,therearefourdatabytes.)
Forexample,assumethatcontrolmodule‘B’isconfiguredforonemeasurementmode(FBB),andthevalueis78.Thestringfromthecontrolmoduleisasfollows:
0x1c, ‘B’, 0x00, 0x4E, 0x0A.(atotaloffivebytes)
or
0x00, 0x4E(atotaloftwobyteswithSuppressHeaderoption)
Nowassumethatcontrolmodule‘B’isconfiguredforFBBandLBBwithvaluesof74and303,respectively.Thestringfromthecontrolmoduleisasfollows:
0x1c,’B’, 0x00, 0x4A, 0x01, 0x2F, 0x0A(atotalofsevenbytes)
or
0x00, 0x4A, 0x01, 0x2F(atotaloffourbyteswithSuppressHeaderoption)
A.3 Max Meas Mode Command String
MaxMeasModecausesthecontrolmoduletoretainthemaximummeasurementvaluesforagivenobject.ThesevaluesaretransmittedeitherimmediatelyafterthecontrolmoduleisclearedorwhenpromptedbytheHost.TheMaxMeasModeCommandStringisafour-bytestringthatappearsasfollows:
• Controlbytewithdecimalvalue248
• ControllerID(oneof15ASCIIlettersAthroughO,asspecifiedinthePSF)
• MaxMeasCommandTransmit(ASCIIletterT).
• Terminationbytewithdecimalvalue13
Thecommandstringisfurtherdefined:
/*the below C code will define an array called msg which will contain the Max Meas Mode Command String*/
unsigned char msg[4]; /*declare four byte unsigned character array using C language */msg[0]=248; /*control byte */msg[1]=65; /*assume the controller ID is the letter A */msg[2]=84; /*assume initiation byte which is the ASCII letter T */msg[3]=13; /*termination byte */
Whenthehostsendsthisstring,thecontrolmodulesendsthemaximumvaluesstoredfromthepreviousscannedobject.Ifthesensorispresentlyscanninganobjectwhenthemessageissent,thecontrolmodulewillgivethemaximumvaluesforthepresentobject.
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Appendix B: Glossary
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Appendix B: Glossary
Blanked Beam: Abeamthatis“ignored”bythereceiver,asaresultofablankingprogrambeingappliedtoit.Beams(orgroupsofbeams)areblankedwhenacomponentorfixturewillremaininormovethroughthelightscreenarray;blankingtheaffectedbeamspreventsthecomponentorfixturefromcausingfalseoutputs.
Blocked Beam: Abeamthatisobstructedbetweentheemitterandthereceiver,andisnotblanked.
Clear Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasamadeorunblockedbeam).
Excess Gain: Ameasurementoftheamountoflightfallingonthereceiverfromtheemitteroverandabovetheminimumamountrequiredforoperation.A-GAGEHigh-ResolutionMINI-ARRAYemittersandreceiversautomaticallyperformanAlignmentproceduretoequalizetheamountofexcessgainateachelementalongthearray.
Host: AcomputerorprocesscontrollerthatcontrolsandreceivesinputfromtheHigh-ResolutionMINI-ARRAYSystem,and/orotherequipmentandsystemswithinafactory.
Made Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasanunblockedorclearbeam).
Unblocked Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasamadeorclearbeam).
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P/N64118rev.B
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