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High-Resolution MINI-ARRAY Features Excelsathigh-speed,preciseprocess
monitoringandinspectionapplications
Acomprehensivecombinationofscanningmodesandoutputs:
10measurement(ScanAnalysis)modes 3scanningmethods
Beamblanking Selectablecontinuous,gatedorhost-
controlledscaninitiation Programmablehysteresisforhighandlow
limits Serialcommunicationoptions
Storablescanningprogramseliminatereprogrammingforrepeatedapplications
Non-volatilememorystoresalignmentsettings
AllmodelswithbothAnalogandDiscrete
outputs AnalogoutputNullsetting
Lowcost,comparedwithsimilarsystems
Precisionsensorshavea380mmto1.8m(15"to6')workingrange
Widefieldofview,easilyaligned
Alignmentroutineequalizesgainofeachbeamforreliable2.5mm(0.10")objectdetectionthroughoutthearray
HostcomputerorPLCmaybeusedtoinitiate
scansand/orprocessscandata Uniqueaddressesforupto15control
modulesononeEIA-485PartyLine
A-GAGE
High-Resolution MINI-ARRAY
Instruction ManualFor controllers with 2 analog and 2 discrete outputs
Printed.in.USA. 04/12 P/N 64118 rev.C
971410thAvenueNorthMinneapolis,MN55441Phone:763.544.3164 Fax:763.544.3213
Email:[email protected]
WARNING . . .Not To Be Used for Personnel Protection
ThesesensorsdoNOTincludetheself-checkingredundantcircuitrynecessarytoallowtheiruseinpersonnelsafetyapplications.Asensorfailureormalfunctioncancauseeitheranenergizedorde-energizedoutputcondition.ConsultyourcurrentBannerSafetyProductscatalogforsafetyproductswhichmeetOSHA,ANSIandIECstandardsforpersonnelprotection.
!
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P/N64118rev.B2
Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
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Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
P/N64118rev.B
Table of Contents
Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel: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 .. . . . . . . . . . . . . . . . . . . . . . . . . . . 123.1 EmitterandReceiverMounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 ControlModuleMounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.3 Hookups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.3.1 EmitterandReceiverHookups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3.2 Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3.3 Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Control Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 CommunicationsSetup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1.1 PingRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1.2 FactorySettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2 SystemAlignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.1 Push-buttonAlignmentRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.2 SoftwareAlignmentRoutine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.2.3 Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.3 ProgrammingControlModuleResponse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5.3.1 SelectedControllerandSerialConnection. . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3.2 ControlModeSelection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3.3 ScanningMethod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.3.4 ScanAnalysisModeSelection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.3.5 AnalogOutputConfiguration(AnalysisModeAssignment). . . . . . . . . . . . 26 5.3.6 ZeroValue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.7 DiscreteOutputConfiguration(AnalysisModeAssignment). . . . . . . . . . . 28 5.4 SerialCommunicationwithaHostController . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.1 SerialDataTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.2 TransmissionType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.3 SerialOptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.5 TransferofPSFtotheControlModule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.5.1 SavingandRecallingPSFFiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5.2 PSFOutputAnalysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5.3 QuitandExit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6. System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1 DiagnosticsIndicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.2 DiagnosticsRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix A: Data Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
A.1 HostModeCommandString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.2 SerialDataFormatandHeaderString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.2.1 ASCIIFormatDataTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A.2.2 BinaryFormatDataTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A.3 MaxMeasureModeCommandString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Appendix B: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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P/N64118rev.B
System Description
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Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
1. System Description
TheA-GAGEHigh-ResolutionMINI-ARRAY measuringlightscreenisidealforapplicationssuchason-the-flyproductsizingandprofiling,edge-guidingandcenter-
guiding,looptensioningcontrol,holedetection,partscountingandsimilaruses.
1.1 System Components
AtypicalA-GAGEHigh-ResolutionMINI-ARRAYSystemhasfivecomponents:ahigh-resolutionemitter/receiverpair,eachwithquick-disconnect(QD)connectors;oneoffourcompactcontrolmodules;andquick-disconnectcablestoconnectthem.SoftwareisincludedtointerfaceanyPC-compatiblecomputer(runningWindowsX, Vista,or 7)withthecontrolmoduleforSystemconfiguration.AhostcomputerorPLCmaybeusedtocontroland/orreceiveinputfromtheSystem.
Sensorsareavailablein12arraylengthsfrom163mmto1951mm(6.4"to76.8"),in163mm(6.4")increments,aslistedinthetableonpage5.TheemitterhastwocolumnsofinfraredLEDsspaced5mm(0.2")apart.Thecolumnsareseparatedby7.5mm(0.3")andarestaggeredfromeachotherby2.5mm(0.1").Thereceiverisconfiguredoppositetotheemitter,withtheidenticallengthandbeamspacing.Thishigh-resolutionsensorpairiscapableofdetectinga12.7-mmlongby2.54-mmdiameter(0.5"by0.1"dia.)cylindricalrod(heldperpendiculartothesensor).Thesensorshaveawidefieldofviewandareeasilyaligned,withaworkingrangeof380mmto1.8m(15"to6').
Eachofthefourversatilemicrocontroller-basedcontrolmodulesareconfiguredusingaPC-compatiblecomputerrunningWindows XP, Vista, or 7,andthesuppliedsoftware,viathebuilt-inRS-232interface.
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Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
P/N64118rev.B
System Description
Emitter/Receiver
Model
MAHE64AEmitterMAHR64AReceiver
1626mm(64.0")
MAHE6AEmitterMAHR6A Receiver
MAHE77AEmitter
MAHR77AReceiver
1951mm(76.8")
MAHE13A EmitterMAHR13A Receiver
MAHE19A EmitterMAHR19A Receiver
MAHE26A EmitterMAHR26AReceiver
MAHE32A EmitterMAHR32AReceiver
MAHE38AEmitter
MAHR38A ReceiverMAHE45AEmitterMAHR45AReceiver
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 theSystem with the suppliedsoftware and anyPC-compatible computer(running WindowsXP,Vista, or 7), via an RS-232cable.
High-ResolutionReceiver
High-Resolution Emitter
DIN-Rail MountableControl Module
Figure 1-1. A-GAGE High-Resolution MINI-ARRAY System components
Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
ControllerModel Solid-StateDiscrete Outputs AnalogOutputs
MAHCVP-1 2PNP (2)0-10VSourcing
MAHCVN-1 2NPN (2)0-10VSourcing
MAHCIP-1 2PNP (2)4-20mASinking
MAHCIN-1 2NPN (2)4-20mASinking
Quick-Disconnect Cables
Communication Cables
CableModel Description
Sensor Cables
QDC-515C 4.6m(15')Cable,straightQDconnector
QDC-525C 7.6m(25')Cable,straightQDconnector
QDC-550C 15.2m(50')Cable,straightQDconnector
Communication Cables
MASC 2m(6.5')DB9,straightRS-232cable
Control Module Models
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P/N64118rev.B
System Description
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Figure 1-2. A-GAGE High-Resolution MINI-ARRAY System features
1.2 System Features
Built-infeaturessimplifytheoperationoftheA-GAGEHigh-ResolutionMINI-ARRAYsystem.High-resolutionemittersandreceivers,availablein12lengths,featuretwo
closelyspacedcolumnsofbeamstoprovideaprecise,high-resolutionlightscreenforexactingapplications.TheAlignmentroutineautomaticallyequalizestheexcessgainofeachbeamforreliable2.5-mm(0.10")objectdetectionthroughoutthearrayandstoresthisdatainnon-volatilememory.TheAlignmentroutineneednotbeperformedagainunlessthesensingapplicationchanges,oriftheemitterand/orreceiverismoved.Programmablebeamblankingaccommodatesmachinecomponentsorotherfixturesthatmustremaininormovethroughthelightscreen.Blankingmaybesetautomaticallyaspartoftheinitialsetup,orbyusingtheincludedconfigurationsoftware.
Built-indiagnosticprogrammingandeasy-to-seeindicatorsonthesensorsandthecontrolmodulemakealignmentandtroubleshootingeasy(Figure1-2).TheemitterhasaredLEDthatsignalsproperoperation.ThereceiverhasthreebrightLEDs:greensignalsthatthesensorsareproperlyaligned;yellowsignalsmarginalalignment;andredsignalsmisalignmentorablockedcondition.Thecontrolmodulehasfourstatusindicators:3redLEDssignaldiscreteoutput#1conducting(seesection5.3.5formoreinformationonoutputs),Alarmoutput(discreteoutput#2)conducting,andgatesignalreceived;agreenLEDsignalsthatthesensorsareproperlyaligned.AsegmentedLEDDiagnosticsIndicatorprovidesdetailedsystemstatususingsingle-digitcodes;aperiodintheindicatorwindowindicatesthepresenceofblanking.Akeytothediagnosticscodesisprintedonthesideofthecontrolmoduleforsimplifiedtroubleshooting.
TheA-GAGEHigh-ResolutionMINI-ARRAYSystemprovidesawideselectionofsensingandoutputoptions,including:measurement(scananalysis)modesandscanningmethodsthatcandeterminethetargetobjectslocation,overallsize,totalheightortotalwidth.Scanningmaybecontinuousorcontrolledbyahostprocesscontrolleroragatesensor.Upto15systemsmaybenetworked.
High-Resolution Emitter
DIN-Rail-Mountable Control Module
High-Resolution Receiver
HIGH RESOLUTION MINI-ARRAY CONTROLLER
ALIGNMENTSWITCH
POWER
POWER
DIAGNOSTICSINDICATOR
2 - TX3 - RX5 - COM
RS-232
MAHCVP-1
OUTPUT
ALARM
GATE
ALIGN
1
+
+
16-30V dc1A MAX
10-30VDCGATE
DOUT1
150mAMAX
0-10VOLTS
25mA(MAX)VOUT1
EMTR RCVR
2 3 4 5 6 7 8 9 10 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0
F1+12VCOMDRNT/RT/R
BR BU BK WH
T X T X
+ 10-30VDC
ALIGN
0-10VOLTS25mA(MAX)
VOUT2+V
ALARM
150mAMAX
+V
7.6 mm (0.30")
2.5 mm(0.10")
5.1 mm(0.20")
Diagnostics Indicator
Alignment Button
Red Discrete Output #1 LED
RedOperationalLED
Green Alignment LED
Red Blocked LED
Yellow MarginalAlignment LED
Red Alarm (Discrete Output #2) LEDRed Gate LED
Green Align LED
RS-232 Port
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Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
P/N64118rev.B
System Description
Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel: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-compatiblecomputerrunningWindowsXP, Vista, or 7..Themenu-drivenprogramwalkstheuserthroughthemanyscanningandoutputoptions.Afterthedesiredoptionsareselected,theusercansavethecombinationofselections
inaParameterSetupFile(PSF),andstoreitinthecontrolmodulesnon-volatilememory.AnynumberofPSFsmaybestoredinthesystemconfigurationcomputerandrecalledasneeded.
Thesoftwarealsoprovidesalignmentanddiagnosticsroutines.AnAlignmentscreendisplaystheindividualstatusofeachbeaminthelightscreen,aswellasthetotalnumberofbeamsintheSystem,andtotalsofbeamsblocked,madeandblanked.Built-insystemdiagnosticscanbeusedtoassessemitterandreceiverhardwareerrors.
1.3 Typical Applications
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P/N64118rev.B
Specifications
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Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
Environmental Rating
Minimum Object Sensitivity 2.5mm(0.1")
NEMA4,13(IP65)
Sensor Scan Time 1.8millisecondsto58.4milliseconds,dependingonscanningmethodandsensorlength;seeSection5.3.3fordetailedinformation
Power Requirements 12Vdc2%,suppliedbycontroller
Status Indicators Emitter: RedLEDlightstoindicateproperemitteroperationReceiver: Greenindicatessensorsaligned Yellowindicatesmarginalalignmentofoneormorebeams Redindicatessensorsmisalignedoroneormorebeam(s)blocked
Connections Sensorsconnecttocontrollerusingtwo5-conductorquick-disconnectcables(oneeachforemitterandreceiver),orderedseparately.Seepage5foravailablelengths.UseonlyBannercables,whichincorporateatwistedpairfornoiseimmunity.Cablesmeasure8.1mm(0.32")indiameterandareshieldedandPVC-jacketed.Conductorsare20gauge(0.9mm).Emitterandreceivercablesmaynotexceed75m(250')long,each.
Construction Aluminum,withblackanodizedfinish;acryliclenscover
Operating Conditions Temperature:0to+50C(+32to122F)Maximum relative humidity:95%at50C(non-condensing)
Emitter/Receiver Range 380mmto1.8m(15"to6')
2. Specifications
2.1 Emitter and Receiver Specifications
Certifications
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Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
P/N64118rev.B
10.2 mm(0.40")
L3
38.1 mmSquare(1.50")
53.8 mm(2.12")
2.5 mm(0.10")
18.3 mm(0.72")
47.2 mm(1.86")
L1
71 mm(2.8")
R13 mm (0.5")Minimum Bend
L2
Figure 2-1. Emitter and receiver dimensions
With mounting bracket flanges inWith mounting bracket flanges out
Emitter/ReceiverModel
Housing Length Distance Between Bracket Holes
MAHE6AEmitter
MAHR6A Receiver236mm(9.3") 268mm(10.5")
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")
MAHE45AEmitter
MAHR45AReceiver
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): Lightstoindicate GATEinputisactiveAlign (green): LightstoindicateemitterandreceiverarealignedDiagnostics indicator: (Keyoncontrollersidelabel)IdentifiesSystemerrorsandstatus
Inputs Sensor input: Emitterandreceiverwireinparalleltofiveterminals.Gate input: Opticallyisolated,requires10to30Vdc(7.5kimpedance)forgatesignalRemote alignment input: Opticallyisolated,requires10to30Vdc(7.5kimpedance)foralignment
sequencesignal
Discrete (Switched) Outputs NPN outputs:OpencollectorNPNtransistorratedat30Vdcmax.,150mAmax.PNP outputs: OpencollectorPNPtransistorratedat30Vdcmax.,150mAmax.All discrete outputs: OFF-state leakage current:
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P/N64118rev.B
81.0 mm(3.19")
115.0 mm(4.53")
106.0 mm(4.17")
35.0 mm(1.38")
DIN mounting slot
Slot for M3.5 screws (2)5.5 mm(0.22")
69.0 mm(2.72 ")
5.0 mm(0.20")
96.0 mm(3.78")
Figure 2-2. Control module dimensions
Specifications
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P/N64118rev.B
Installation and Mechanical Alignment
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Banner Engineering Corp. Minneapolis,U.S.A.www.bannerengineering.comTel:763.544.3164
3. Installation and Mechanical Alignment
3.1 Emitter and Receiver Mounting
BannerMINI-ARRAYemittersandreceiversaresmall,lightweight,andeasytohandleduringmounting.Themountingbrackets(supplied)allow30rotation.
Fromacommonpointofreference,makemeasurementstolocatetheemitterandreceiverinthesameplanewiththeirmidpointsdirectlyoppositeeachother.MounttheemitterandreceiverbracketsusingthevibrationisolatorsandM4Kepsnuts(allsupplied).SeeFigure3-1.StandardM4or#8-32boltsmaybesubstituted(andthevibrationisolatorseliminated)insituationswheretheemitterandreceiverarenotsubjectedtoshockorvibrationforces.Whiletheinternalcircuitsoftheemitterandreceiverareabletowithstandheavyimpulseforces,thevibrationisolatorsdampenimpulseforcesandpreventpossibledamageduetoresonantvibrationoftheemitterorreceiverassembly.
Figure 3-1. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting hardware
MountingSurface
M4 KepsNut (8)
M4 x 10 mmSlotted Hex Headwith Compression
Washer (2)
MountingBracket
Emitter orreceiver
Anti-VibrationMount (4)
MountingBracket
Washer
Nut
Studs: M4 x 0.79.5 mm (0.38") long
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P/N64118rev.B
NON-QD EndQD End
Min. R.
Full R (4)
4.8 mm (2)(0.19")
38.1 mm
(1.50")
6.4 mm R(0.25")
44.5 mm(1.75")
6.4 mm(0.25")
57.2 mm(2.25")
3.8 mm(0.15")
10.2 mm (2)(0.40")
30.5 mm(1.20")
34.8 mm(1.37")
11.9 mm(0.47")
Slots have clearancefor M4 bolts (supplied)
and allow 30 rotation
13.2 mm(0.52")
6.8 mm (2)(0.27")
3.0 mm(0.12")
24.6 mm(0.97")
53.8 mm(2.12")
Material: Cold Rolled SteelFinish: Black, Zinc Plated
Chromate Dip
Figure 3-2. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting bracket
dimensions
Installation and Mechanical Alignment
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Mounttheemitterandreceiverintheirbracketsandpositiontheredlensesofthetwounitsdirectlyfacingeachother.Theconnectorendsofbothsensorsmustpointinthesamedirection.Measurefromoneormorereferenceplanes(e.g.thebuildingfloor)tothesamepoint(s)ontheemitterandreceivertoverifytheirmechanicalalignment.Ifthesensorsarepositionedexactlyverticalorhorizontaltothefloor,acarpenterslevel
isusefulforcheckingalignment.Astraightedgeorastringextendedbetweenthesensorsalsohelpswithpositioning.Alsocheckbyeyeforline-of-sightalignment.Makeanynecessaryfinalmechanicaladjustments,andhand-tightenthebrackethardware.SeeSection6forinformationonalignmentindicatorsandSection5forinformationontheuseofthealignmentsoftwarewhichissuppliedwiththecontroller.
3.2 Control Module Mounting
ThecontrolmodulemustbeinstalledinsideanenclosurewhichhasaNEMA(orIEC)ratingsuitablefortheoperatingenvironment.
MountingdimensionsforthecontrollerareshowninFigure2-2,onpage11.ThecontrolmoduleissuppliedwithM3.5hardwarefordirectmountingtoasurface,orthemodulemaybemountedontostandard35mmDINrail.
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POWER
1
+
+
16-30V dc1 A max
10-30V dcGATE
SIGNAL
+30V dc max
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROWN
BLUE
DRAIN(BARE)
BLACK
WHITE
DISCRETEOUTPUT#1
150 mAmax
EMITTER andRECEIVER CABLES
TX TX
DISCRETEOUTPUT#2 (ALARM)
+ 10-30V dc
ALIGN
RS-485
+30V dc max
150 mAmax
25 mAmax
0-10VANALOG
OUTPUT #2
25 mAmax
0-10VANALOG
OUTPUT #1
Figure 3-3. MAHCVN-1 hookup
POWER
1
+
+
16-30V dc1 A max
10-30V dcGATE
SIGNAL
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROWN
BLUE
DRAIN(BARE)
BLACK
WHITE
DISCRETEOUTPUT#1
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
POWER
1
+
+
16-30V dc1 A max
10-30V dcGATE
SIGNAL
+30V dc
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROWN
BLUE
DRAIN(BARE)
BLACK
WHITE
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 TX
RS-485
Load
Figure 3-5. MAHCIN-1 hookup
+16 30V dc+16 30V dc
POWER
1
+
+
16-30V dc1 A max
10-30V dcGATE
SIGNAL
4-20 mAANALOGOUTPUT #1
4-20 mAANALOG
OUTPUT #2
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROWN
BLUE
DRAIN(BARE)
BLACK
WHITE
EMITTER andRECEIVER CABLES
DISCRETEOUTPUT#2 (ALARM)
+ 10-30V dc
ALIGN
Load Load
150 mAmax
DISCRETEOUTPUT#1
150 mAmax
TX TX
RS-485
Figure 3-6. MAHCIP-1 hookup
3.3 Hookups
RefertoFigures3-4,3-5,3-6,and3-7fortheappropriatehookupinformation.
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2 - TX3 - RX
5 - COM
RS-232
5 3 2
Installation and Mechanical Alignment
Serial CommunicationRS-232:AllA-GAGEHigh-ResolutionMINI-ARRAYSystemsmaycommunicatewitha
hostcomputerorcontrollerviaRS-232orRS-485serialprotocol.SeeSection5.3.1forselectablecommunicationsparameters.PrepareanRS-232cableusingamaleDB-9connectorwithconnectionsasshowninFigure3-8.
NOTE:DONOTuseanullmodemRS-232cable
RS-485: RS-485serialportislocatedatterminals#18(TX)and#19(TX).
DB-9 Pin # Function
2 Transmit(TX)
3 Receive(RX)
5 Ground(GND)
3.3.1 Emitter and Receiver Hookups
Emittersandreceiversconnecttogetherinparalleltoterminals#4through#8ofthecontrolmodule(identicalforallcontrolmodulemodels).SeeFigures3-3,3-4,3-5,and
3-6forwirecolorinformation.
3.3.2 Inputs
System Power: Connectasourceof16to30Vdc,ratedat1amporgreater,tocontrolmoduleterminals#1(+)and#2(-).Connectagoodearthgroundtoterminal#3toprovideelectricalandRFnoiseimmunitytotheSystem.
NOTE:Removepowerbeforemakingotherconnectionstothecontroller.
Gate Signal: Asourceof10to30Vdcswitchedtoterminals#12(+)and#13(-)
providesagatinginput(ifrequired).Thegatingvoltagetypicallyisswitchedbytheopen-collectoroutputtransistorofadcsensingdevice.ThegatesignalcontrolsscanningwhenoneoffourGateoptionsisselectedintheControlModeSelectionmenuofthePSFconfigurationroutine(seeSection5.3.2).
Align: Asourceof10to30Vdcswitchedtoterminals#14(+)and#15(-)providesaremotemeansofrunningtheautomaticalignmentandblankingroutines.TheswitchsequenceisidenticaltotheproceduredescribedinSection5.2.1fortheAlignment
switchonthefrontofthecontrolmodule.
Control ModuleAnalog Outputs
(Terminals #10 and 16)Discrete Outputs*
(Terminals #9 and 20)
MAHCVN-1Figure3-3
0to10VSourcing15mAmax.
NPNopen-collector30Vdcmax.150mAmax.
MAHCVP-1Figure3-4
0to10VSourcing15mAmax.
PNPopen-collector30Vdcmax.
MAHCIN-1Figure3-5
4to20mASinking
16to30Vdc
NPNopen-collector30Vdcmax.150mAmax.
MAHCIP-1Figure3-6
4to20mASinking
16to30Vdc
PNPopen-collector30Vdcmax.
150mAmax.*NOTE:DiscreteOutput#2islabeledAlarmonthecontrolmodule.Figure 3-8. DB-9 connections between the
control module and the PC
Trim braided shield flushwith cable
Trim foil shield flushwith cable
Uninsulateddrain wire
Figure 3-7. Emitter and receiver cablepreparation
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NOTE:Thedrainwireistheuninsulated
strandedwirewhichrunsbetweenthe
braidedshieldandthefoilshield.Thefoil
shieldandthebraidedshieldshouldbe
removedatthepointwherethewiresexit
thecable.
3.3.3 Outputs
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4. Software Installation
The High-Resolution MINI-ARRAY software CD includes an installation routine that quickly and easily loads the MINI-ARRAY configuration programinto your computer. The High-Resolution MINI-ARRAY configuration program requires approximately 50 MB of hard disk space. Install as follows:
1. Use the Parameter Setup Software CD included with the controller, or download (www.bannerengineering.com) as required.
2. Insert the Software CD into the CD drive.
If the program does not auto-start, browse to your CD drive, click Setup.exe, then select START, then select RUN.
2. The Welcome dialog box will appear. Select Next, and follow the prompts in the dialog boxes as they appear.
4. The installation program then decompresses the files. A status dialog box monitors the progress of the installation.
5. An Installation Completed dialog box appears. Select OK. Reboot your computer for the changes to take effect.
After the software is installed, a MINI-ARRAY shortcut icon is placed on your desktop. Double-click on the MINI-ARRAY icon to launch the program, then
follow the configuration and setup procedures described in Section 5 of the primary manual.
Figure 4-1. MINI-ARRAY software installation: dialog boxes
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Figure 5-1. Options menu, serial portselection
Figure 5-2. MINI-ARRAY menu
Figure 5-3. Screen showing the result of acompleted Ping routine
5. Control Module Configuration
TheA-GAGEHigh-ResolutionMINI-ARRAYcontrolmoduleiseasilyconfiguredusingaWindowsmenu-styleroutine;theconfigurationroutinerequirestheBanner-supplied
HRMAsoftwareandaPC-compatiblecomputer(runningWindows XP, Vista, or 7)AserialdataconnectionismadebetweenthecomputerandtheDB9connectoronthecontrolmodule.
5.1 Communications Setup
Afterinstallingthesoftware,attachtheserialcommunicationcablebetweenthecontrolmoduleandthePC.(NOTE:IfanRS-232interfaceisused,onlyonecontrolmoduleisallowedonthelineatanyonetime.)TheminimumconnectionstothecontrolmodulesDB-9connectorareshowninFigure3-8.
LaunchtheHigh-ResolutionMINI-ARRAYprogramandconfiguretheserialcommunicationsportofthePC.SelecttheOptionsmenufromtheHigh-ResolutionMINI-ARRAYmainmenu(seeFigure5-1).TheprogramsupportsserialcommunicationviatheCOM1-COM20.portofthecomputer.Highlightthedesiredserialporttoselectit(abulletwillappearnexttotheselectedoption),thenselectSave Settings on Exittostoretheserialportselection,ifitisnotalreadyON(abulletwillappearnexttotheoption,ifitisON).
Parityisselectedherealso:Even,OddorNone.
5.1.1 Ping Routine
ThePingroutinemustbeperformedduringSystemconfiguration,andbeforeanyDiagnostic,Alignment,orEditroutine.Theroutinepollsallcontrolmodulesonthecommunicationsline(one,inthecaseofthestandardRS-232line,orupto15modules,onanRS-485circuit).Itthenisusedtoselectanindividualcontrolmoduleforconfigurationoralignment.
Ifneeded,applypowertotheSystemcontrolmoduleandallowtheSystemtocompleteitspower-uproutine.Press F5oraccesstheMINI-ARRAYmenuandselectPingtoperformthePingroutine.AllconnectedcontrolmoduleswillthenidentifythemselveswithanIDvalueandbaudrate;theroutinetakesapproximately15to20seconds.AfterthePingisperformed,allvalidcontrolmoduleIDvalueswillappearinachartonthescreen,undertheirappropriatebaudrates(seeFigure5-3).ControlmodulesareidentifiedinthechartasX.PointtoavalidIDwiththemousepointerandclicktoselectacontrolmodule.SystemDiagnostics,Alignment,orEditroutinesmaynowbeperformedfortheselectedcontrolmodule.
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5.1.2 Factory Settings
Ofthe15availablecontrolmoduleIDvalues(AthroughO),thefactorysoftwaresettingisA.Selectablecommunicationbaudratesare9600,19200,and38400;the
factorysettingis9600.Seesection5.3.1forinformationonchangingthesesettings.
5.2 System Alignment
Theemitter/receiverpairshaveawidefieldofviewandareeasytoalign.Therecommendeddistancebetweentheemitterandreceiverrangesfrom15"to72".(Shortersensorseparationcanbeachieved;pleaseconsultfactoryfordetails.)TheAlignmentprocessshouldbeperformedatSysteminstallationandrepeatedeverytimeoneorbothofthesensorsismoved.AlignmentoftheSystemcanbespecifiedautomaticallyusingeithertheAlignmentroutineoftheconfigurationsoftwareortheAlignmentswitchonthecontrolmodulesfrontpanel.
TheSystemalsomaybealignedremotely,usingpins14and15ontheterminalblock.Apply10to30Vdcpowertothepins(seepage14)toapproximatethepush-buttonprocedure.(Forexample,applyinputsignalfor3secondstoaccessAlignmentmode.)
Makesurethesensorshavebeenwiredasshowninsection3.3.Applypowertothecontrolmoduleviaterminals#1and#2(16to30Vdc).TheDiagnosticsIndicatorwillshowthesensorsgoingthoughapower-uptest:firstthereceiver,thentheemitter.AfterthesensorshavebeentestedandtheSystemisreadyforservice,theDiagnosticsIndicatorwillshowor.;seeFigure5-4.
5.2.1 Push-button Alignment RoutineAtinstallationorwhenevertheemitterand/orreceiverismoved,theSystemshouldbere-aligned.PresstheAlignmentswitchonthecontrolmodulefrontpanelfor3seconds,afterwhichtimetheletterAwillappearontheDiagnosticsIndicator;theSystemislearningaclearcondition.Rotatethesensorsasrequired(butdonotchangethedistancebetweenthem).WhenthegreenAlignmentLEDisdisplayedonthecontrolmoduleandreceiver,thesensorsareadequatelyaligned.ToleaveAlignmentmode,againpresstheAlignmentswitchfor3seconds.
Duringthealignmentprocedure,thesystempollseachreceiverchanneltomeasureexcessgainandperformsacoarsegainadjustment.Whenthesystemexitsthealignmentprocedure,eachchannelssignalstrengthisstoredinnon-volatilememory.Thesystemisnowreadyforoperationanddoesnotrequirere-alignmentunlesstheemitterorreceiverismoved.
Figure 5-4. Diagnostics Indicator showing aclear condition
ALIGNMENTSWITCH
R
DIAGNOSTICSINDICATOR
OUTPUT
ALA
RM
GAT
E
ALIGN
30V
150mA MAXEMTR RCVR
ALIGNMENTSWITCH
R
DIAGNOSTICSINDICATOR
OUTPUT
ALARM
GATE
ALIGN
30V
150mA MAXEMTR RCVR
Denotes
Blanking
With Blanking OFF
With Blanking ON
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5.2.2 Software Alignment Routine
ThegreenLEDindicatoronthereceiverandalsoonthecontrolmodulecontinuously
displaysAlignmentstatus.Whenallunblankedbeamsareclear,thegreenAlignmentindicatorswillbeON.Tobetterunderstandblocked,clearandblankedbeams,launchtheAlignmentroutine(pressF8orselectAlignmentundertheMINI-ARRAYmenu).Thescreenwillshowthestateofallofthebeamchannels,groupedintosetsof16.
KeyinformationprovidedontheAlignmentscreenisthesensorsize,plusthenumberofbeamsblocked,made,andblanked.Thesensorsizeisgiventhetitleoftotal;thisreferstothetotalnumberofbeamchannelsinthearray.Thenumberofbeamsblockedisarunningtotalofblockedbeams,excludinganyblankedbeams.Themadevalueisacountofunblockedbeams.Theblankedvalueisacountofthenumberofbeamchannelsthatareblanked(channelsthatareignoredformeasurementmodeapplications;seesection5.2.3).
TheAlignmentscreenprovidesthefollowingfunctions:Start,Stop,Step,ClearBlankingFields,RestoreControlmoduleSettings,AutoBlanking,AbortAutoBlanking,SavetoFile,ReadFromFile,Cancel,OK,andEdit.Toaccessanyofthesesub-routinesfirstpressStop,thentheselectedoption.
StartcommandcausesthecontrolmoduletocontinuouslyscanandreportAllChannelData.Thisdataisusedtoupdatethestateofeachbeamchannel.
Stopcommandcausesthecontrolmoduletostopscanning.
Stepcommandproducesonescanandthenstopsuntilanothercommandisissued.
Clear Blanking Fieldscommandisaquickwaytoremoveblankingspecifications.
Restore Control Module SettingswillrecalltheblankingspecificationsineffectpriortoAlignment/Blankingbeingentered.
Auto Blankingcommandisusedtoscananddeterminewhichbeamsareblocked;blockedbeamsautomaticallybecomeblankedbeams.TheAutoBlankingvaluescanthenbeAcceptedorAborted.
Editisusedtocontroltheblankingspecificationsofanychannelmanually.Thisisusefulforaddinganynumberofblankedbeamchannelsaboveand/orbelowablankedobjecttoallowforvibrationorothermovementoftheobjecttobeignored.
BlankingspecificationscanbesavedandreadfromacomputerfileusingtheSave ToFileandRead From Filecommands.
Figure 5-5. Alignment screen
Control Module Configuration
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5.2.3 Blanking
Ifamachinefixtureorotherequipmentwillcontinuouslyblockoneormorebeams,theaffectedbeamchannelsmaybeblanked.
TheBlankingoptioncausesthecontrolmoduletoignorethestatusofblankedbeamsformeasurementmodecalculations.Forexample,ifamachinefixtureblocksoneormorebeamsduringSystemoperation,theoutputdatawillbeincorrect;ifbeamsblockedbythefixtureareblanked,theoutputdatawillbecorrect.Blankingmaybeconfiguredusingthepush-buttonAlignmentswitchonthecontrolmodule,orbyusingthesystemsoftwareandacomputer.
Push-Button Blanking Setup RoutineTo specify blanking using the control modules Alignmentswitch,(seeFigure5.4)positiontheobjectorparttobeignoredinthepathofthebeamsbeforebeginningtheAlignmentroutine.PresstheAlignmentswitchfor3seconds;theDiagnosticsIndicatorwillshowtheletterA.PresstheAlignmentswitchagain,butthistimeonlymomentarily(about0.5secondsmax.).TheDiagnosticsIndicatorwillshowtheletterbtoindicateitisreadytolearntheblankingpattern.Again,momentarilypresstheAlignmentswitchtosettheblankingfields.Boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshowA.(theperiodfollowingtheAindicatesthatblankingisinuse).Thebeamsblockedduringtheroutinearenowblanked.ToreturntoRunmode,againpresstheAlignmentswitchfor3seconds.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing.(seeFigure5-4).
System Software Blanking Setup RoutineTo specify blanking using the System software,theprocedureissimilar.Positiontheobjecttobeblankedinthepathofthebeams(thiscanbedoneatanytimebeforebeginningtheblankingroutine).PerformthePingroutinetoselectthepropercontrolmodule,thenpressF8orselecttheAlignmentoptionfromtheMINI-ARRAYmenu.Fromthescreenmenu(Figure5-6),selectStop;theDiagnosticsIndicatoronthecontrolmodulewillshowtheletterA.SelectAuto Blanking (Figure5.7);theDiagnosticsIndicatorwillshowtheletterb.SelectAccept Auto Blanking;boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshowA.(theperiodfollowingtheAindicatesthatblankingisinuse).Thebeams
blockedduringtheroutinearenowblankedandappearastheletterBonthegridinsteadof0;ifyouwishtoblankadditionalbeams,usetheEditkeytomanuallysetadditionalblanking(seenextpage).ToleaveAlignmentmode,selectOK.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing.(seeFigure5-4).
Scanning Mode Limitations for Blanking:AllblankingfeaturesareavailablewithContinuousScanmode.Forsingle-anddouble-edgescan,blankingislimitedtofourblankingfields.Otherblankingfeaturesareignored.
Figure 5-6. Alignment screen, showing beams #1-11 blocked
Figure 5-7. Alignment screen, showing beams #1-11 blanked
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To accommodate parts or components that will move throughthe array,blankingmaybemanuallyadjustedforoneormoreindividualbeamchannels.AfterusingtheSystemsoftwaretospecifyblanking,selectEditfromtheAlignmentscreen;theDiagnosticsIndicatorwillcontinuetoshowtheletterbanda
gridwillappearonthecomputerscreen(Figure5-8).Thebeamsarenumberedfromthesensorscabledends,withthebeamclosesttothecablebeingbeam#1.Tosettheblankingfields,clickeachgridboxrepresentingabeamyouwishtoblank.
Clickingagainonablankedbeamchannelwillremovetheblankingspecification.Rowsofchannelscanbeselectedorclearedoftheblankingspecificationbyplacingthecursordirectlytotheleftoftherowtobeselectedandclickingthemouse;therowshouldbehighlighted.SelecttheBlankSelected(toaccepttheblankingstatus)orClear Selected(torejecttheblankingstatus)option.ToleaveAlignmentmode,selectOK.Boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshowA..WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing.(seeFigure5-4).
Figure 5-8. Edit channel blank state screen, showing beam #22 andbeams #35-42 blanked; beams #65-80 are highlighted,ready to be selected for blanking
5.3 Programming Control Module Response
TheParameterSetupFile(PSF)Configurationroutine(seeFigure5-9)isusedtoconfigurethecontrolmoduleforaspecificapplication.AccessthePSFConfigurationscreen(afterperformingthePingroutinetoselectacontrolmodule,section5.1.1)by
selectingEdit PSF (F4)fromtheMINI-ARRAYmenu.TheEditPSFprocessmayalsobeperformedwithnocontrolmoduleselected,toconfigureandsaveaPSFformultiplecontrolmodules.Insuchacase,somefieldsonthePSFConfigurationscreenwillnotbeaccessible.
Theprocessofconfiguringthecontrolmoduleinvolvesselectingamongoptionsforeachoftheparameterslistedinthissection,includingserialcommunication,controlmode,scanningmethod,scananalysismode,serialtransmission,andanalog/discreteoutputs.Theresultingcombinationofoptionscausesthecontrolmoduletoreactasrequiredfortheapplication,tochangesinthelightscreen.
TheconfigurationprocessproducesaParameterSetupFile(PSF).PSFfilesmaybesavedandretrievedascomputerfilesviatheFile Save PSFandFile Retrieve PSFcommands(seesection5.4.5).Onceconfigured,aPSFmaybesenttothecontrolmoduleviatheSend PSFcommand.Likewise,thePSFcurrentlyloadedintothecontrolmodulemaybedisplayedbyusingtheUpload PSFcommand.
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Figure 5-9. Use the PSF Configuration screen to program each control module individually
Serial TransmissionSpecifiesthetypeofdatatransmittedfromthecontrolmoduletoitshost
aftereachscan.Measurement Mode Result:DatatransmittedwillreflecttheAnalysisModeselections.All Mode:Transmitsalldata.Max. Meas. Mode: Sendsonlythelargestmeasurementineachmeasuringevent,todecreasetransmissionsizeandspeedresponse.Choosetosendwhenthearrayisclearorsendatthehostsrequest.Transmission Type: ASCIIorBinary,definestheformatinwhichthedatawillbesent.Serial Options:SuppressClearDataorSuppressHeadertodecreasetransmissionsizeandspeedresponse.
Analysis (Measurement)Mode Selection
Choosethemeasurementoptionthatbesttellsyou
thesizeand/orposition
ofobjectsastheyrelatetothearray.
Control Mode SelectionContinuous Mode:Thecontrol
moduleconstantlypollsthearrayforstatus.
Host Mode:Thecontrolmodulepollsthearrayforstatuswhenpromptedbyahostcontroller.
Gate Mode: Thecontrolmodulepollsthearrayforstatuswhen
promptedbyaninputfromaGatesensor.
Scanning MethodStraight scanpollseachbeam
sequentiallytodeterminethetargetobjectsoverallsize.Thisisthemost
accurateandprecisemeasurement,butalsothemosttime-consuming.
Single Edge scanrequiresthetargetobjecttoblockbeam1(closestto
thesensorscabledends),thenconductsatime-savingbinary
searchtohuntforthetargetsoverallheight(onevariableedge).
Double Edge scanconductsatime-savingsearchoftheentire
arraytohuntforthetargetsoverallwidth(twovariableedges).
Set Point andHysteresis SelectionAssignsthesetpointtodeterminewherewithinthearraytheoutput(s)willrespondandhysteresisvaluestosmoothoutputresponse.
Trigger/Trigger Channel NumberMaybeusedtotrigger(orgate)thescansequenceofanotherA-GAGE High-Resolution MINI-ARRAYcontroller;instraightscanningmode,itdefineswhenduringeachscandiscreteOutput#2willchangestate.
Scan #: (1-9)Analogoutputsareupdatedwithanaveragevalueofthedatareceivedduringtheselectednumberofscans;discreteoutputsrespondonlyifthereceiveddataisidenticalforalloftheselectednumberofconsecutivescans.
Analog and DiscreteOutput Assignment
Assignsananalysis(measurement)mode
toeachoutput.
Alarm:CausesthecontrolmoduletoturnondiscreteOutput#2whenevertheSystemdetectsasensingerrororiftheopticalsignalbecomesmarginal.
Selected ControllerIdentifiesthespecificcontrolmodulebeing
configured.
Serial CommunicationChangestheidentificationandbaudrateofthecontrollerbeingconfigured.
Zero ValueZeroValueisusedtospecifytheanalogoutputwhenthe
measurementmodevalueiszero.TheusercanspecifyavalueofLAST,NULL,orSPAN.
LAST:Outputholdsthelastnon-zerovaluebeforethelightscreenbecameclear.
NULL: Providestheminimumvalue.
SPAN:Providesthemaximumvalue.
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5.3.1 Selected Controller and Serial Communication
TheSelectedControllerboxdisplaysinformationaboutthecontrolmodulebeingconfigured.TwoofthesesettingsmaybechangedintheSerialCommunicationbox.
ThesettingsselectedanddisplayedintheseboxesarethoseusedtoidentifythecontrolmoduleduringthePingroutine(section5.1.1).
Controller ID(assignedaletter, AthroughO)isusedtoidentifyeachindividualcontrolmodulewhenmultiplediscrete-outputcontrolmodules(upto15)areconnectedononeEIA-485partyline.NOTE:AnalogoutputcontrolmodulesdonotofferRS-485communication;chooseanyIDletter(AthroughO)whenprogrammingananalog-outputcontrolmodule.
Baud Rateisthedatacommunicationratebetweenthecontrolmoduleandthecomputerusedforconfigurationandalsotheprocesscontroller.Choosefromthreevalues:9600, 19200,and38400.
Parity: SelectOdd,Even,orNone.AllcontrollersononeEIA-485partylineshould
havethesameparitysettings.
5.3.2 Control Mode Selection
Thecontrolmodedeterminesthemethodusedtocontrolscanningofthelightscreenarray(seeFigure5-11).Choosefromthreemaincontrolmodes:
ContinuousScanmode, SerialHostCommandmode,and Gatemode(whichitselfhasfouroptions)
In Continuous Scan Mode,thecontrolmodulebeginsanewscanassoonasitupdatestheoutputsfromthepreviousscan.Thisisthefastestscancontrolmethod;itisusedinmostanalogoutputapplicationsandwhenevercontinuousupdatingoftheoutputsisacceptable.
Host ModeallowsthecontrolmoduletocommunicatewithahostcomputerorcontrolmoduleviaRS-232(allmodels)orRS-485(discrete-outputmodelsonly)serialprotocol.ThehostdirectsthecontrolmoduletoscanondemandandreceivestheoutputdatafromthecontrolmoduleinbinaryorASCIIform.Baudratesof9600,19200,and38400areselectableintheSerialcommunicationsmenu(section5.3.1).(SeeAppendixAformoreinformationonHostmodedataformat.)
Gate ModeactivatesanopticallyisolatedexternalGateinputbetweenterminals12(+)and13(-)ofthecontrolmodule.TheGateinputhasimpedanceof7.5kandaccepts
a10to30Vdcsignal.AdcdevicesuchasaphotoelectricsensororopticalencodertypicallysuppliestheGateinput.Gateinputsignalsmustbegreaterthan150microsecondsinduration;thetimebetweensuccessiveGateinputsmustbegreaterthantheminimumscantimeforthelightscreenarray(seesection5.3.3forscantimeinformation).
Gatemodehasfouroptions: Gate ON: thecontrolmodulewillscanaslongasthegateisactive. Gate OFF: thecontrolmodulewillscanwheneverthegateisnotactive. Gate ON/OFF: thecontrolmodulewillscanonceforeachgatetransitionfromONtoOFF. Gate OFF/ON:thecontrolmodulewillscanonceforeachgatetransitionfromOFFtoON.
Figure 5-11. Control Mode selections(PSF Configuration screen)
Figure 5-10. Selected Controller and SerialCommunicationselections (PSF Configurationscreen)
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,orbottom).Ifthefirstbeamisblocked,thesensorwillperformabinarysearchtohuntforthelastbeamblocked.Single-EdgeScanworksasfollows:
1. Thereceiverscansonlythebottombeamuntilthatbeamisblocked.
2. Whenthebottombeamisblocked,thesensorlookstoseewhetherthemiddlebeamisblockedormade(unblocked).
3. Ifthemiddlebeamismade(unblocked),thesensorchecksthebottomquarterbeam;ifthemiddlebeamisblocked,thesensorchecksthetopquarterbeam.(Thisiscalledabinarysearch;seeFigure5-13.)
4. Thisroutinecontinuestonarrowthefielduntiltheedgeisfound.
Notethatthereceiveralwayschecksthebottombeamfirst,andonlyifthatbeamisblockeddoesthebinarysearchcontinue.Therefore,Single-EdgeScanwillnotworkininstanceswhereanitemthatdoesnotblockthefirstbeamistobemeasured.Single-EdgeScanisalsoineffectiveiftheobjectdoesnotpresentacontinuousblockedpattern.Inotherwords,Single-EdgeScanisusedforsingle,solidobjectsthatblockthefirstbeam.
Figure 5-12. Scanning Method selections(PSF Configuration screen)
DIAGNOSTICS
E rrorNo.
E rrorTy pe
ErrorNo.
ErrorType
SystemOK
4
EmitterError
1
Align/blank
5
Se rialComm
2
Output Short
6
EEPROM
3
E/ RMismatch
7
CPUE rror
4
Rece iv erError
8
Null/Span
1PO
WER
2 -TX
3 -RX
5 -COM
ALIGNM
ENT
SWITC
H
D IAGNO
STIC S
INDICA
T OR
RS-232
MAHCN-
1
HIGH R
ESOLUT
IONM IN
I-ARRAY
CONTRO
LLER
23
45
67
89
1011
121 3
1 415
1617
1819
20
1
+
NC
NC10-30Vd
c
GATE
NC
TXTX
+12V
BR
EMTR
RCVR
BU
BK
5W ir es
W H
30V
150mAM
AX
OUTPUT#1
COMDRN T/
R T/ R
16-30Vdc
1AMAX
POW ER
23
45
67
89
1011
1213
1415
1617
1819
20
OUTPUT
ALARM
GATEA
LIGN
+
F1
30V(MAX
)
150mAM
AX
ALARM
10-30Vdc
ALI GN
RS- 485
+
High-Resolution
Emitter
MAHCN-1
Control ModuleHigh-Resolution
Receiver
Beam #1 of 64
Blocked
Beam #48
Clear
Beam #32
Blocked
Beam #44
Clear
Beam #40
Blocked
Beam #42
Blocked
Beam #43
Blocked
Step #2Step #1 Step #3
Step #4 Step #5 Step #6 Step #7
Figure 5-13. Finding an edge using a binary search
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Double-Edge Scanisusedtodetecttwoedgesofasingleobject,forexample,boxwidthmeasurements.Double-EdgeScanrequirestheselectionofastepsize:2,4,8,16or32beams.Thesensorusesthestepstoskipoverbeams.Double-EdgeScanworksasfollows:
1. Thesensoractivatesbeam#1(thebeamclosesttothesensorcableend).2. Thesensoractivatesthenextbeam,determinedbythestepsize.(Forexample,if
thestepsizeis2,beam#3isnext;ifthestepsizeis8,beam#9isnext.)
3. Aslongastheactivatedbeamisunblocked(ormade),thesensorwillcontinuethesteppingroutineuntilablockedbeamisfound.
4. Whenablockedbeamisfound,abinarysearchisconductedtofindtheobjectsbottomedge.
5. Whenthebottomedgeisfound,thesensorbeginssteppingagainthroughthearrayuntilthesensorfindsthenextunblockedbeam.
6. Abinarysearchisagainperformedtofindthesecondedge.
Notethatthisscanningmethodsacrificesobjectdetectionsizeforspeed.Similarto
Single-EdgeScan,Double-EdgeScanhassomerestrictions:theobjectshouldprovideasolidobstruction;thesizeoftheobjectwilldeterminethemaximumstepsize(Figure5-14).
Sensorresponsetimeisafunctionofsensorlengthandscanningmethod.TypicalscantimesareshowninFigure5-15.
Step Size
Number of Beams
MinimumObjectDetectionSize
5mm(0.2")
10mm(0.4")
20mm(0.8")
40mm(1.6")
80mm(3.2")
Maximum Scan Times (in milliseconds)
ArrayLength
StraightScan
Single-EdgeScan
Double-Edge Scan
Step2 Beams
Step4 Beams
Step8 Beams
Step16 Beams
Step32 Beams
163 mm
(6.4") 5.8 1.8 3.4 2.7 2.5 2.6
325 mm(12.8")
10.6 1.9 8.1 5.1 3.6 3.0 2.7
488 mm(19.2")
15.0 2.1 11.5 6.8 4.5 3.4 3.0
650 mm(25.6")
20.1 2.1 14.9 8.5 5.3 3.9 3.2
812 mm(32.0")
24.9 2.1 18.3 10.1 6.1 4.2 3.5
975 mm(38.4")
30.0 2.1 21.7 11.8 7.0 4.7 3.6
1138 mm(44.8")
34.5 2.1 25.0 13.5 7.9 5.1 3.8
1300 mm(51.2")
39.3 2.1 28.4 15.2 8.7 5.5 4.1
1626 mm(64.0")
48.0 2.3 35.1 18.6 10.4 6.4 4.5
4.8
1788 mm(70.4")
53.6 2.3 38.5 20.3 11.2 6.8 4.7
Figure 5-14. The effect of step size onminimum object detection size
Figure 5-15. The effect of sensor length and scanning method on scan time (typical)
Control Module Configuration
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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
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5.3.4 Scan Analysis Mode Selection
Thecontrolmodulemaybeprogrammed,ifdesired,foranyoneortwoofsevenScanAnalysis(measurement)Modes.Eachselectedmodemaybeassignedindividuallyto
anoutput(seesection5.3.5or5.3.6).Thebeamsinthearrayarenumberedinsequence,withbeam#1locatedatthecabledendoftheemitterandthereceiver.
Beam Location Modes First Beam Blocked (FBB): ThecontrolmoduleidentifiesthelocationoftheFirst
BeamBlocked.
First Beam Made (FBM):ThecontrolmoduleidentifiesthelocationoftheFirstBeamMade(unblocked).
Last Beam Blocked (LBB):ThecontrolmoduleidentifiesthelocationoftheLastBeamBlocked.
Last Beam Made (LBM):ThecontrolmoduleidentifiesthelocationoftheLastBeamMade(unblocked).
Middle Beam Blocked (MBB):ThecontrolmoduleidentifiesthelocationoftheMiddleBeamBlocked,midwaybetweenthefirstandlastbeamsblocked.
Beam Total Modes Total Beams Blocked (TBB): Thecontrolmoduletotalsthenumberofblocked
beams.
Total Beams Made (TBM): Thecontrolmoduletotalsthenumberofmade(unblocked)beams.
Contiguous Beams Blocked (CBB):Thecontrolmoduleidentifiesthelargestnumberofconsecutivelyblockedbeams.
Contiguous Beams Made (CBM):Thecontrolmoduleidentifiesthelargestnumberofconsecutivelymadebeams.
Transitions (TRN):Thecontrolmodulecountschangesfromblockedtoclearand
cleartoblocked.Forinstance,ifbeams6-34areblocked,thenthereisaclear-to-blockedtransitionfrombeam5tobeam6,andablocked-to-cleartransitionfrombeam34tobeam35.Transitionmodecanbeusedtocountobjectswithinthearray.
TheAnalysisMode(s)programmedmaybeassignedtoanyoneoftheavailableoutputs(seeFigure5-18).EachoutputcanbesetforMEAS1, MEAS2, MEAS1InvertedorMEAS2 Inverted.
5.3.5 Analog Output Configuration (Analysis Mode Assignment)
Analogoutputs#1and#2mayeachbeassignedtooneoftheanalysismodesdescribedinsection5.3.4.WhentheselectedScanAnalysisModeinvolvesfirstor
lastbeamblockedormade(unblocked),theassignedoutputwillvaryinproportiontothebeamnumberidentifiedduringascan.WhentheScanAnalysisModeinvolvestotalbeamsblockedormade,thatassignedoutputwillvaryinproportiontothetotalbeamscountedduringascan.
Notethatthepull-downmenususedforassignmentoftheScanAnalysisModestotheanalogoutputsincludetwoInvertedselections.WheneitherMEAS1 InvertedorMEAS2 Invertedisselected,thatanalogoutputwilldecreaseasthemeasurementmodevalueincreases.Aninvertedoutputwillbeatfullscale(Spanvalue)whenthescananalysisvalueiszero;andatmaximumscananalysisvalue,theoutputwillbeattheNullvalue.
Figure 5-18. Assigning an Analysis Mode toeach Analog Output(PSF Configuration screen)
Figure 5-17. Examples of MINI-ARRAY scananalysis modes
Figure 5-16. Scan Analysis Mode Selection(PSF Configuration screen)
Last Beam Made (LBM)First Beam Made (FBM)
Receiver
Emitter
8
16
24
32
40
48
Last Beam Blocked (LBB)First Beam Blocked (FBB)
Receiver
Emitter
8
16
24
32
40
48
Total Beams Made (TBM)Total Beams Blocked (TBB)
Receiver
Emitter
8
16
24
32
40
48
InLastBeamBlockedmode,
lastbeamis#43of48
InFirstBeamBlockedmode,
firstbeamis#15of48
InLastBeamMademode,
lastbeamis#37of48
InFirstBeamMademode,
firstbeamis#26of48
InTotalBeamsMademode,
34of48possiblebeamsare
made
InTotalBeamsBlockedmode,
14of48possiblebeamsare
blocked
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TheNullandSpanrangesmaybeadjustedasfollows:
Toreadthenewvaluesonthemeter,clickonNullorSpan Update.ClickontheOKbuttontosavethenewsettingsandreturntheprogramtothePSFConfigurationscreen.ClickingontheCancelbuttonreturnstheprogramtothepreviouslysavednullandspansettings.
NOTE:NullandSpanarefactorysettospecifiedvaluesandusuallyrequirenochanges.
Scan #Providesawaytosmoothoutputresponseandavoidunstableanalogoutputconditions.Themenuallowsselectionoffrom1to9scans(seeFigure5-20).Foranalogoutputs,ifscan#issetatmorethan1,thescananalysisvalueisaveragedforalloftheselectednumberofconsecutivescans,preventingdipsandspikesintheoutputs.
Fortotalbeamvalues(TBBandTBManalysismodes),programmingofblankedbeams(section5.2.3)willaffecttheproportionalanalogoutputs.Blankedbeamsareignoredbothinthenumberofblockedormadebeamsandthetotalnumberofbeams.Forexample,ifa64-beamarrayhas20blankedbeamsand22oftheremaining44beamsareblocked,theoutputvalueswillbeatmid-range.
5.3.6 Zero Value
Zerovalueisusedtospecifytheanalogoutputwhenthemeasurementmodevalueiszero.TheusercanselectananalogoutputofLAST,NULL,orSPAN.
LAST: Outputholdsthelastnon-zerovaluebeforethelightscreenbecameclear.NULL: ProvidestheminimumvalueSPAN: Providesthemaximumvalue.
TheNull/SpanConfigurationscreen(Figure5-19),maybeusedtoadjustthezeroandfullscalereadingforeitheranalogoutput.TodisplaytheNull/SpanConfigurationscreclickontheNull/SpanbuttonatthebottomofthePSFConfigurationscreen(Figure5-Eachoutputisindependentandmustbeadjustedseparately.AdjusttheNullandSpanvalueseitherbymovingtheslidebars,orbyenteringanewvalueonthekeyboard.
To Measure:Analog Voltage Output:Connectthevoltmeterbetweenterminals10or16(+)and17().
Analog Current Output:Connecttheammeterbetweenterminals10or16()and1(+).
AnalogOutput Type
Null Span
Minimum Maximum Minimum Maximum
Voltage 10mV 2.3V 4.8V 10.1V
Current 3.9mA 7.8mA 11.9mA 20.2mA
Figure 5-19. Null/Span Configuration screen
Figure 5-20. Scan # (PSF Configurationscreen)
Figure 5-21. Zero Value (PSF Configurationscreen)
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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).
NexttoeachdiscreteoutputassignmentmenuareLowandHighSet Pointboxes.Thenumberineachboxidentifiesabeaminthearray(beam#1beingclosesttothecabledendoftheemitterandthereceiver).TheLowandHighSetPointsmaybechangedbyclickingonaboxandenteringanewnumber.
WhentheselectedScanAnalysisModeinvolvesfirstorlastbeamblockedormade(unblocked),theassignedoutputwillenergizewhenthebeamidentifiedduringascanfallswithintherangeofthesetpoints.WhentheScanAnalysisModeinvolvestotalbeamsblockedormade,thatassignedoutputwillenergizewhenthevalueoftotalbeamscountedduringascanfallswithintherangeofthesetpoints.
Notethatthepull-downmenususedforassignmentoftheScanAnalysisModestothediscreteoutputsincludetwoInvertedselections.WheneitherMEAS1 InvertedorMEAS2 Invertedisselected,thatdiscreteoutputwillde-energize(turnOFF)wheneverascananalysisvaluefallswithintherangeofthesetpoints.
Hysteresisvaluesforeachendofthesetpointrangemayalsobeset(Figure5-22).Hysteresisdeterminestheamountofchangethatmustoccurateachsetpoint(HighandLow)tocausetheassociatedoutputtochangestate.Hysteresispreventsunstableoutputconditionswhenthescananalysisvalueexactlymatchesoneofthesetpoints.ThedefaulthysteresissettingisonebeamlessthantheLowSetPointandonebeammorethantheHighSetPoint.
Scan #Providesanotherway,inadditiontohysteresissettings,tosmoothoutput
response.Outputsareupdatedonlyaftertheselectednumberofidentical(withinthehysteresislimits)scans.Themenuallowsselectionoffrom1to9scans.Fordiscreteoutputs,thescananalysisvaluemuststayeitherinsideoroutsidethehysteresislimitsforalloftheselectednumberofconsecutivescans,inorderfortheoutputtorespond.SeeFigure5-23.
Alarm and TriggerDiscreteoutput#2(only)hastwoadditionaloptions:AlarmandTrigger.
Alarm:Output#2energizeswhenevertheSystemdetectsasensorerror(suchasadisconnectedcable)orwhenevertheexcessgainofoneormorebeamsbecomesmarginal.
Trigger: canbeusedtogateasecondcontrolmodulewhenContinuousScanMethodisalsoused.Whenthecontrolmoduleisinstraightscanningmode,Trigger ChannelNumberdefinesthebeamnumberduringascanatwhichthetriggeroutputwilloccur(Figure5-23).TheTriggeroutputisa100microsecond(0.0001sec.)pulse.Ifthecontrolmoduleissetforsingleordoubleedgescan,theTriggerpulsewillcomeattheendofthescan(Trigger Channel Numberwillbeignored).
Figure 5-23. Scan # (PSF ConfigurationScreen)
Figure 5-24. Trigger Channel
Figure 5-22. Assigning an Analysis Mode to each Discrete output(PSF Configuration screen). Alarm and Triggeroutput options are available only for DiscreteOutput #2.
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5.4 Serial Communication with a Host Controller
ThecontrolmodulecommunicateswithahostprocesscontrollerviaRS-232orRS-485protocolandatthebaudratespecifiedintheSerialCommunicationsbox
(section5.3.1).TheSystemprovidesanumberofdatatransmissionoptions.
5.4.1 Serial Data Transmission
TheserialtransmissionportionofthePSFConfigurationscreenactivatestheserialport(s),specifiesthedataformat,andprovidesdatasuppressionoptions.Thesesettingsarerequiredtoallowacontrolmoduletocommunicatewithahostcomputerorprocesscontroller.IfNo Serial Communicationisselected(thedefaultsetting),theserialport(s)willnottransmitsensingdata.
Measurement Mode Result: datatransmittedwillbethevaluesoutputfortheScan
AnalysisModeselections.UptotwoScanAnalysisModeselectionscanbeactive.
ALL Mode: thestatusofeachbeaminthelightscreenarraywillbetransmittedforeach scan. InALLmode,blankedchannelsaretransmittedasunblocked(orclear)beams.
Max Meas Mode: thecontrolmodulerecordsthemaximummeasurementvalueregisteredwhilethelightscreenisblocked.Thatdatamaybetransmittedtothehosteitherwhenthearrayisclearattheendofthesensingevent(selectSend On Clear),orwhenpromptedbythehost(selectSend On Request).Thismodereducestheamountofserialdatasent.
5.4.2 Transmission Type
Transmissiontypedefinestheformatinwhichdataissent.TheASCIIoptioncausesthecontrolmoduletosenddatainthreeASCII-codedbytes.TheBinaryoptioncausesdatatobesentinbinaryformat,reducingtheamountofdatapermeasurementmodefromthreebytestotwo.Formoreinformationonthedataformats,refertoAppendixA.
Figure 5-25. Serial Data Transmissionoptions (PSF Configurationscreen)
Control Module Configuration
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5.4.3 Serial Options
TheSerialOptionsboxprovidestwooptions:Suppress Clear DataandSuppressHeader.
Suppress Clear Dataprovidesonemethodtoreducetheamountofdatabeingtransmittedbythecontrolmodule,accomplishedbynotsendingdatawhennoobjectisdetected.Thecontrolmoduletransmitsserialdataonlywhenoneormoreunblankedbeamsofthelightscreenarrayareblocked.Whenthearraygoesfromblockedtoclear,dataissentoneadditionaltime,indicatingtheclearcondition.
Suppress Headerisusedtopreventtransmissionofthethree-byteidentificationstring(headerstring)associatedwitheitherASCIIorBinarydataformats.Theheaderstringconsistsoftwobytesatthestartofthedata,andaterminationbytetomarktheendoftheserialtransmission.SeeAppendixAformoreinformationonserialdataformats.
5.5 Transfer of PSF to the Control Module
AftermakingalloftheselectionsinthePSFConfigurationscreen,thePSFmaybesenttothecontrolmodulebyclickingtheSend PSFbutton(seeFigure5-26).ThiscommandloadsthePSFintothenon-volatilememoryofthecontrolmodule,andautomaticallyoverwritesthecurrentPSF.TheprogramwillconfirmthatthePSFwasaccepted,orwillnotifytheuserofchangesrequiredtothePSF.
TocheckthevaluesofthePSFcurrentlyloadedintothecontrolmodule,selectUploadPSF.ThecurrentPSFwillbedisplayedonthePSFConfigurationscreen.
Figure 5-26. PSF Output options (PSF Configuration screen)
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5.5.1 Saving and Recalling PSF Files
ToplacethedisplayedPSFintoafilethatcanberetrievedatanytime,selectFileSave PSF (Figure5-26).WhenaskedifyouwanttosavethePSFtoafile,selectYes.
AsubscreentitledFileSavewillappear(Figure5-27).Overtype*.psfintheFileNameentryboxwiththenameofthefiletobestored(upto8characters),plusthe.psfextension;thenselectOK(orpressEnter).ThePSFwillbestoredontheselecteddrive(defaultisc:)andtheprogramwillautomaticallyreturntothePSFConfigurationscreen.
ToretrieveafiledPSF,selectFile Retrieve PSF.TheFileBoxsubscreenwillappear(Figure5-28).SelectthedesiredPSFfromtheFileNamelistandselectOK(orpressEnter).TheselectedPSFwillloadtothePSFConfigurationscreen,anditcanthenbeloadedintothecontrollerusingtheSend PSFcommand.
5.5.2 PSF Output AnalysisToviewactivityinthearrayinresponsetothecurrentlyloadedPSF,selectExecute(Figure5-26).TheMeasurementOutputscreenwillappear(Figure5-29);selectRun.Thetablewilldisplaythestatusfortheselectedmeasurementmode(s),includingthePresentvalueandtheHighandLowvaluesfortheRunperiod.
SelectStoptofreezethedata.SelectSteptoinitiateasinglescanofthearraytosimulateasnapshotofwhatisviewedbythearrayattheinstantthatStepisselected.
UseoftheExecutecommandisespeciallybeneficialfortestingtheresponseofagatedsystem.RunsimulatestheContinuousScanningmode,andStepsimulatesagateinputcommand.
5.5.3 Quit and Exit
ToclosethePSFConfigurationscreen,selecteitherQuitorExit (Figure5-26).SelectingQuiterasestheEditPSFScreenandsendstheuserbacktotheMainWindow;thepresentPSFScreenvaluesarenotretained.TheExitcommandissimilartotheQuitcommand,excepttheuserwillbepromptedtosavetheconfigurationvaluestoaparametersetupfile(PSF).
Figure 5-27. FileSave subscreen of thePSF Configuration screen,accessed with the File SavePSF command
Figure 5-28. FileBox subscreen of the PSFConfiguration screen,accessed with the FileRetrieve PSF command
Figure 5-29. Measurement Output subscreen ofthe PSF Configuration screen,accessed with the Executecommand
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6. System Diagnostics
Systemdiagnosticsmaybeperformedusingthestatusanddiagnosticsindicatorsonthecontrolmoduleandsensors,orbyusingtheDiagnosticssoftwareroutine,ora
combinationofthetwo.
6.1 Diagnostics Indicators
NOTE:StatusindicatorsappeartofreezeifthecontrollerhasbeenconfiguredforGateorHostmode(Section5.3.2),andnosignalispresenttocauseascanupdate.
DIAGNOSTICSError No. Error Type/Action
System is OK
A / b Align / blank Status
1 Output Short Checkoutputload&wiring
2
E / R Mismatch
Systemmustusesamelengthemitterandreceiver
3Receiver Error Checkreceivercable Replacereceiver
4Emitter Error Checkemittercable Replaceemitter
5 Serial Comm Checkserialcable
6EEPROM ReconfigurePSF Replacecontrolmodule Reconfigureblanking
7 CPU Error Replacecontrolmodule
8 Null / Span Status
Figure 6-2. Key to System DiagnosticsIndicator codes
RedOperationalLED
Green Alignment LED
Red Blocked LED
Yellow MarginalAlignment LED
High-Resolution
Emitter
High-Resolution
ReceiverDIN-Rail-MountableControl Module
HIGH RESOLUTION MINI-ARRAY CONTROLLER
ALIGNMENTSWITCH
POWER
POWER
DIAGNOSTICSINDICATOR
2 - TX3 - RX5 - COM
RS-232
MAHCVP-1
OUTPUT
ALARM
GATE
ALIGN
1
+
+
16-30V dc1A MAX
10-30VDCGATE
D OUT 1150mA MAX
0-10VOLTS25mA (MAX)
V OUT 1
EMTR RCVR
2 3 4 5 6 7 8 9 10 1 1 12 1 3 14 1 5 16 1 7 18 1 9 20
F1+12VCOMDRNT/RT/R
BR B U BK WH
T X T X
+ 10-30VDC
ALIGN
0-10VOLTS25mA (MAX)
V OUT 2+V
ALARM150mA MAX
+V
Diagnostics Indicator
Alignment Button
Red Discrete Output #1 LEDRed Alarm (Discrete Output #2) LED
Red Gate LEDGreen Align LED
RS-232 Port
Figure 6-1. A-GAGE High-Resolution MINI-ARRAY System diagnostics and status indicators
Bright,easy-to-seeLEDindicatorsonbothsensorsandonthefrontpanelofthecontrolmoduleprovideanongoingdisplayofthesystemsoperatingstatus.
Control Module:OUTPUT:(red)displaysthestatusofDiscreteOutput#1.
ALARM: (red)displaysthestatusofDiscreteOutput#2.Thisoutputmaybeassignedtoananalysismode,oritmaybeusedasaSystemDiagnosticsalarmorasaTriggeralarmtogateanotherA-GAGEHigh-ResolutionMINI-ARRAYSystem.
GATE:(red)displaysthestatusoftheGateinput.
ALIGN: (green)indicatesproperemitter/receiveralignmentandaclear,unblockedlightscreen.ThisindicatorisONwheneitherthegreenorboththegreenandyellowLEDsofthereceiverareON.
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Diagnostics Indicator: Thisbright,segmentedLEDdisplayonthecontrolmodulefrontpanelindicatesoneof10Systemstatusconditions,plusthepresenceorabsenceofblanking.(BlankingONcausesaperiodtoappearintheDiagnosticsIndicatorwindow,inadditiontotheSystemsotherstatuscondition.)SeeFigure6-2forthekeytotheseerrortypesandstatusconditions;thischartisalsolocatedonthesideofthecontrol
module.
Emitter:OPERATIONAL:(red)LEDindicatespowertotheemitterisON,andunitisoperational.
Receiver:BLOCKED: (red)LEDindicatessomeofthearraybeamsareblocked.
MARGINAL:(yellow)LEDindicatesthatarrayalignmentismarginal.
ALIGNMENT: (green)LEDindicatesthatarrayalignmentissatisfactory.
Toimprovealignment,adjustthepositionoftheemitterandreceiveruntilthegreenLEDlights,makingsurethatnounblankedbeamsareinterrupted.Thenuseoneofthemethods
inSection5.2torealignthesystem.
6.2 Diagnostics Routine
EmitterorreceiverproblemsmaybefurtherdiagnosedusingtheDiagnosticsroutineincludedwiththeMINI-ARRAYsoftware.LaunchtheprogrambyselectingDiagnosticsundertheMINI-ARRAYmenu(Figure5-2)orbypressingF2.
TheDiagnosticsscreen(Figure6-3)displaysthesizeofeachemitterandreceiver(expressedinthenumberof64-element
boardsitcontains)anditsfunctionalstatus(orstate).Ifanerrorhasoccurred,thespecificproblembeamchannelisidentified.Additionally,ifthereisaproblemwithanemitterorreceivercableconnection,aNo Responsemessageisdisplayed
TheDiagnosticsroutinealsodisplaysthepartnumberanddatecodeofthecontroller,informationthatmaybeusefuliffactory-assistedtroubleshootingbytelephoneisrequired.
Figure 6-3. Diagnostics screen, accessible from the MINI-ARRAY menu
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Appendix A: Data Transmission
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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)andthen
updatesitsoutputsasrequired.ThecontrolmodulethenwaitsforthenextHostCommandmessagebeforeinitiatinganotherscan.
A.2 Serial Data Format and Header String
Theprogrammedmeasurementmodeormodesdeterminethetypeofinformationthatisseriallytransmitted.ForexampleifMeas1issetforFBBandMeas2issetforLBB,thenthedatatransmittedtothehostcontainsthevaluesofthefirstandlastbeamblocked.TheAllmeasurementmodeprovidesthestatusofallbeamstothehost.
Inadditiontomeasurementmodeinformation,thedatatransmissionalsocontainsa
two-bytestartstringandaterminationbyte.Thestartstringconsistsofafirstbytethatdoesnotchange,followedbythecontrollerID.Thefirstbytevalueisahex1Cor28decimal.Attheendofthestring,thecontrolmodulewillplaceaterminationbyte.TheterminationbyeistheASCIIcharacterforalinefeed(hexvalue0A).ThesethreebytescollectivelyarecalledtheSerialHeaderstring.
Figure A-1. Serial Transmission options(PSF Configuration screen)
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A.2.1 ASCII Format Data Transmission
TherearetwowaystouseASCIIformattorepresentdata.Theoneuseddependsuponwhichmeasurementmodesareselected.
For ALL measurement mode,eachdatabyteispresentedinaneight-bitASCIIformatthatconveysthestatusoffourconsecutivechannels(fourconsecutivebeams).Eachsubsequentbyteconveysthestatusofthenextfourchannels,untilthestatusofeverychannelisreported.TheallowabledatavaluesforAllmeasurementmodeareASCIInumbers0to9andASCIIlettersAtoF.Inthetable,a0representsanunblockedbeamchannel,and1representsablockedchannel.
Forexample,assumethata64-channelsystemhasbeenconfiguredfortheAllmeasurementSerialtransmissionoption.Channels1through4areblocked,asischannel63.Theserialstringstartswith0x1c,andtheID(assumeanA)followedby16ASCIIvaluesandterminatedwith0x0A.Thestringwouldappear:
0x1c, A, F, 0,0, 0,0, 0,0, 0,0, 0,0, 0,0, 0,0, 0,4, 0x0a
Thestringshowsthatbeams1through4areblocked,asisbeam63.Allotherbeamsareunblocked.Iftheuserhadrequestedsuppressionoftheheader,then0x1c,A,andthe0x0awouldhavebeendeleted.
For transmitting Measurement mode data,usethreeASCIIbytestorepresenteachmeasurementmode.Forexample,ifMeas1isFBB,Meas2isLBB,themeasuredvaluesare6and120,andthecontrollerIDisB,thedatastringisasfollows:
0x1c B, 0, 0, 6, 1, 2, 0, 0x0a
AswithALLmode,theheaderandcleardatacouldbesuppressed.Forcleardatasuppression,thecontrolmodulesendsthestatusofaclearconditiononlyonthefirstclearscan.Afterthat,thecontrolmodulewillcontinuetoscanbutwillnottransmit
datauntilthesensorisagainblocked.
A.2.2 Binary Format Data Transmission
SimilartoASCIIformat,binaryformatmaybeusedtorepresentdataintwoways.OnemethodinvolvestheAllDatatransmissionmode;theother,Measurementmode.
For All Data transmission mode,thecontrolmodulerepresentsthestatusofeightconsecutivedatachannelsforeachbyte.Eachbitofeachbyteisdirectlyrelatedtothestatusofanindividualchannel.Thefirstdatabyterepresentschannels1through8;theseconddatabyterepresentschannels9through16.Thebitpatternforthefirstand
seconddatabytesisasshowninFigureA-3.
Foreachbitposition,1representsablockedbeamand0representsanunblockedbeam.
Forexample,fora64-channelsystemwithbeams1-6blocked,beam43blockedandbeams62-64blocked,thedatatransmittedfromcontrolmoduleAisasfollows:
0x1c, A, 0xFC, 0x00, 0x00, 0x00, 0x00, 0x20, 0x00, 0x07, 0x0A
Thisstringwouldhavethestartbyte,controllerID,followedbytheeightdatabytesandterminatedwiththe0x0A.Theheaderbytesmaybesuppressedifnecessary.
Appendix A: Data Transmission
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Figure A-2. ASCII data values
Definitions for ASCII Data Values
FortheALLmeasurementmode
Character Ch 4 Ch3 Ch2 Ch1
F 1 1 1 1
E 1 1 1 0
D 1 1 0 1
C 1 1 0 0
B 1 0 1 1
A 1 0 1 0
9 1 0 0 1
8 1 0 0 0
7 0 1 1 1
6 0 1 1 0
5 0 1 0 1
4 0 1 0 03 0 0 1 1
2 0 0 1 0
1 0 0 0 1
0 0 0 0 0
First Data Byte Second Data Byte
ChannelBit
Position ChannelBit
Position
1 7 9 7
2 6 10 6
3 5 11 5
4 4 12 4
5 3 13 3
6 2 14 2
7 1 15 1
8 0 16 0
Figure A-3. Binary data values
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Appendix A: Data Transmission
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For Measurement mode analysis,thebinaryformatusestwodatabytesforeachmeasurementmode.(Ifwehaveonemeasurementmode,thentherearetwodatabytes.Fortwomeasurementmodes,therearefourdatabytes.)
Forexample,assumethatcontrolmoduleBisconfiguredforonemeasurementmode
(FBB),andthevalueis78.Thestringfromthecontrolmoduleisasfollows:
0x1c, B, 0x00, 0x4E, 0x0A.(atotaloffivebytes)
or
0x00, 0x4E(atotaloftwobyteswithSuppressHeaderoption)
NowassumethatcontrolmoduleBisconfiguredforFBBandLBBwithvaluesof74and303,respectively.Thestringfromthecontrolmoduleisasfollows:
0x1c,B, 0x00, 0x4A, 0x01, 0x2F, 0x0A(atotalofsevenbytes)
or
0x00, 0x4A, 0x01, 0x2F(atotaloffourbyteswithSuppressHeaderoption)
A.3 Max Meas Mode Command String
MaxMeasModecausesthecontrolmoduletoretainthemaximummeasurementvaluesforagivenobject.ThesevaluesaretransmittedeitherimmediatelyafterthecontrolmoduleisclearedorwhenpromptedbytheHost.TheMaxMeasModeCommandStringisafour-bytestringthatappearsasfollows:
Controlbytewithdecimalvalue248
ControllerID(oneof15ASCIIlettersAthroughO,asspecifiedinthePSF)
MaxMeasCommandTransmit(ASCIIletterT).
Terminationbytewithdecimalvalue13
Thecommandstringisfurtherdefined:
/*the below C code will define an array called msg which will contain the Max Meas Mode
Command String*/
unsigned char msg[4]; /*declare four byte unsigned character array using C language */
msg[0]=248; /*control byte */
msg[1]=65; /*assume the controller ID is the letter A */
msg[2]=84; /*assume initiation byte which is the ASCII letter T */
msg[3]=13; /*termination byte */
Whenthehostsendsthisstring,thecontrolmodulesendsthemaximumvaluesstoredfromthepreviousscannedobject.Ifthesensorispresentlyscanninganobjectwhenthemessageissent,thecontrolmodulewillgivethemaximumvaluesforthepresentobject.
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Appendix B: Glossary
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Appendix B: Glossary
Blanked Beam: Abeamthatisignoredbythereceiver,asaresultofablankingprogrambeingappliedtoit.Beams(orgroupsofbeams)areblankedwhenacomponentorfixturewillremaininormovethroughthelightscreenarray;blankingtheaffectedbeamspreventsthecomponentorfixturefromcausingfalseoutputs.
Blocked Beam: Abeamthatisobstructedbetweentheemitterandthereceiver,andisnotblanked.
Clear Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasamadeorunblockedbeam).
Excess Gain: Ameasurementoftheamountoflightfallingonthereceiverfromtheemitteroverandabovetheminimumamountrequiredforoperation.A-GAGEHigh-ResolutionMINI-ARRAYemittersandreceiversautomaticallyperformanAlignment
proceduretoequalizetheamountofexcessgainateachelementalongthearray.
Host: AcomputerorprocesscontrollerthatcontrolsandreceivesinputfromtheHigh-ResolutionMINI-ARRAYSystem,and/orotherequipmentandsystemswithinafactory.
Made Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasanunblockedorclearbeam).
Unblocked Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasamadeorclearbeam).
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