Banner A-GAGE MINI-ARRAY MAC Series Bedienungsanleitung

Printed in USA 04/12 P/N 43298 rev. F

A-GAGE®MINI-ARRAY®

Measuring Light Screen System (MAC Series Controllers)

Instruction Manual

Features

Controller Models MAC-1, MACN-1, MACP-1,

MACV-1, MACI-1, MAC16N-1, MAC16P-1

(See Section 1.1 for additional, model-specific features)

• MeasuringLightScreensystemforinspectionandprofiling

applications.

• ModularsystemwithcompactcontrollerandavarietyofBMEL/

BMRLseriesMINI-ARRAYemittersandreceivers.

• Sensorsavailablewitheither9.5mm(3/8")or19.1mm(3/4")

beamspacingandwitharraylengthsfrom6"to4'

(in6"increments),plus5'and6'models.

• Controllerisprogrammableforanyoneortwooften

measurementmodes(dependingonmodel)andanyoneoffour

scanningmodes,usingacomputerrunningWindows®.XP,

Vista, or 7 and the Banner-suppliedsoftware

• Softwareisalsosuppliedfordisplayoferroranalysis(via

controllerself-diagnostics)andforsensoralignment.

• Systemstatus,includingalignment,isdisplayedviaLED

indicatorsonthecontrollerandonthereceivers.

• Controllermaybeprogrammedforblankingtoignoreactivityin

oneortwofieldsalongthelengthofthearray.

• Programmablehysteresisatthehighand/orlowlimitofeach

measurementareaprovidessmoothingofoutputresponse;

alsoprogrammablefornumberofconsecutivescansbeforean

outputupdate.

• Separategateinput(e.g.,fromapresencesensor)allowscontrol

ofscaninitiation.

•SupportsserialcommunicationwithacomputerorPLCviaRS-

232Cinterface;enablesacomputerorPLCtoprocessscandata

and/orinitiatescans;serialdatamaybeeitherASCIIorbinary.

WARNING . . . Not To Be Used for Personnel Protection

Never use these products as sensing devices for personnel protection. Doing so could lead to serious injury or death.

ThesesensorsdoNOTincludetheself-checkingredundantcircuitrynecessarytoallowtheiruseinpersonnelsafetyapplications.A

sensorfailureormalfunctioncancauseeitheranenergizedorde-energizedsensoroutputcondition.ConsultyourcurrentBanner

SafetyProductswhichmeetOSHA,ANSIandIECstandardsforpersonnelprotection.

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

1. System Overview ........................................ page 3

1.1 SystemFeatures ............................................... 4

 1.2 SystemComponents ............................................ 7

2. Specifications ........................................... page 9

2.1 EmitterandReceiverSpecifications................................. 9

 2.2 EmitterandReceiverDimensions ................................. 10

 2.3 ControllerSpecifications ......................................... 11

 2.4 ControllerDimensions .......................................... 12

3. Installation and Mechanical Alignment ........................ page 13

3.1 EmitterandReceiverMounting.................................... 13

 3.2 ControllerMounting ............................................ 14

 3.3 EmitterandReceiverHookups .................................... 14

 3.4 ControllerWiringandOutputHookups.............................. 15

 3.5 SystemPower................................................. 18

 3.6 Gate......................................................... 18

 3.7 SerialCommunication........................................... 18

4. Software Installation ..................................... page 19

5. Controller Configuration ................................... page 20

5.1 CommunicationsSetup.......................................... 20

 5.2 AlignmentAnalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

 5.3 Alignment .................................................... 21

 5.4 ParameterSetupFiles(PSFs) ..................................... 22

 5.5 CreatingNewParameterSetupFiles(PSFs) .......................... 25

   5.5.1 AnalysisModeAssignment.................................. 25

   5.5.2 OutputProgramming ...................................... 25

   5.5.3 AnalysisModeSelection.................................... 28

   5.5.4 BlankingSpecifications..................................... 29

   5.5.5 ScanningMethods ........................................ 31

   5.5.6 ControlModeSelection .................................... 32

 5.6 SerialCommunication........................................... 32

 5.7 PSFAssignmentandStorage ..................................... 33

6. System Operation........................................ page 35

6.1 SensorOperatingStatusIndicators ................................ 35

 6.2 ControllerOperatingStatusIndicators .............................. 36

 6.3 DiagnosticsProgram ........................................... 37

Appendix ............................................. page 39

HostModeCommand.................................................... 39

 SerialDataFormat ...................................................... 39

Contents

Table of Contents

P/N 43298 rev. E 3

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

System Overview

TheBannerA-GAGE®MINI-ARRAYmeasuringlightscreenisidealforapplications

suchason-the-flyproductsizingandprofiling,edge-guidingandcenter-guiding,loop

tensioningcontrol,holedetection,partscounting,dieejectionverification,andsimilar

uses.

AtypicalMINI-ARRAYSystemconsistsoffivecomponents:

 •aControllermodule,

 •anemitterandcorrespondingreceiver,and

 •twointerconnectingcables.

Sensorsareavailableinarraylengthsfrom6"to4'(in6"increments),plus5'and6'

arraymodels,aslistedonpage7.Sensorsareavailablewitheither9.5mm(3/8")or

19.1mm(3/4")beamspacing,whichtranslatestoeither32or16beamsperfootof

arraylength.Sensorswith3/8"beamspacinghaveasensingrangeofupto6m(20').

Sensorswith3/4"beamspacinghaveasensingrangeofupto17m(55');5'and6'

arrayshaveshorterrange(seeSpecifications).

Box Profiling

Paint Booth

Profiling

Edge Guiding

Inspection Applications

Figure 1-1. Typical MINI-ARRAY Applications

1. System Overview

4 P/N 43298 rev. E

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

System Overview

1.1 System Features

Built-infeaturessimplifytheoperationoftheA-GAGEMINI-ARRAYsystem.

Programmablebeamblankingaccommodatesmachinecomponentsorotherfixtures

thatmustremaininormovethroughthelightscreen.Blankingissetbyusingthe

includedconfigurationsoftware.SeeSection5.5.4formoreinformation.

Built-indiagnosticprogrammingandeasy-to-seeindicatorsonthesensorsandthe

controlmodulemakealignmentandtroubleshootingeasy(Figure1-2).Theemitter

hasaredLEDthatsignalsproperoperation.ThereceiverhasthreebrightLEDs:green

signalsthatthesensorsareproperlyaligned;yellowsignalsmarginalalignment;and

redsignalsmisalignmentorablockedcondition.Thecontrolmodulehassevenstatus

indicators:5redLEDssignalwhenoutputsareconducting(seeSection3formore

information),Alarmoutputconducting,andgatesignalreceived;agreenLEDsignals

thatthesensorsareproperlyaligned.DIAG1,2,and3LEDsindicatesystemstatus.A

keytothediagnosticscodesisprintedonthesideofthecontrolmoduleforsimplified

troubleshooting(seeSection6.3).

TheMINI-ARRAYSystemprovidesawideselectionofsensingandoutputoptions,

including:measurement(“scananalysis”)modesandscanningmethodsthatcan

determinethetargetobject’slocation,overallsize,totalheightortotalwidth.Scanning

maybecontinuousorcontrolledbyahostprocesscontrolleroragatesensor.Some

models(MAC1,MACP,MACN)supportRS-485,whereupto15systemsmaybe

networked.

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

Emitter

DIN-Rail-Mountable Control Module

Receiver

MINI-ARRAY

CONTROLLER

2 - TX

3 - RX

5 - COM

RS-232

MAC-1

OUT 1

ALARM

GATE

DIAG 1

DIAG 2

DIAG 3

ALIGN

POWER

Red Discrete

Output #1 LED

Red

Operational

LED

Green Alignment LED

Red Blocked LED

Yellow Marginal

Alignment LED

Red Alarm

(Discrete Output #2) LED

Red Gate LED

Green Align LED

RS-232 Port

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

30V

150mA

Max.

ALARM

500mA

Max

OUT 1

WH BK BU

5 Wires

BR-+

RS485

10-30V DC

GATE

L2 L1

16-30V DC

1.2A Max.

14 13 12 11 10 9 8 7 6 5 4 3 2 1

T/RT/R DRN COM +12V F1

EMTR RCVR

P/N 43298 rev. E 5

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

System Overview

1.1.1 Model-Specific Features

Models MAC-1, MACN-1, and MACP-1

•SupportsserialcommunicationwithahostcomputerorPLCviaRS-232orRS-485

interface;enablesacomputerorPLCtoprocessscandataand/orinitiatescans;

serialdatamaybeeitherASCIIorbinary.

•Upto15controllersmaybeassignedseparateIDsandplacedonRS-485partyline.

•MAC-1:Twooutputs:onereedrelayandoneNPNtransistoroutput;eitheroutput

maybeinverted(i.e.,programmedfornormallyopenornormallyclosed).

•MACN-1 and MACP-1:Twodiscreteopen-collectorPNP(currentsourcing)orNPN

(currentsinking)transistoroutputs,dependingonmodel.

Models MACV-1 and MACI-1

•AnalogoutputnullandspancanbeadjustedviaPCinterfaceandsuppliedsoftware.

•Analogoutputsignalcanhaveeitherarisingorfallingslope.

•Analogoutputswillautomaticallyadjusttosensorlength.

•Discreteoutputisanopen-collectorNPN(currentsinking)thatcanbeusedasan

alarm,atrigger,orusedwithanAnalysisModeSelection(outputcapableofbeing

invertedinAnalysisMode).

•MACV-1: Twolinearsourcinganalogvoltageoutputs(0to10volts)andoneNPN

transistoroutput.

•MACI-1: Twolinearsinkinganalogcurrentoutputs(4to20mA)andoneNPN

transistoroutput.

Models MAC16N-1 and MAC16P-1

•Twoadditionalmeasurementmodes:

TRNmodecountsthenumberofclear-to-blockedandblocked-to-cleartransitions;

SEGmodepartitionsthearrayintoupto16regions.

•Controllerhasflexibleblankingcapabilitieswithunlimitedblankingconditions.

Blankingmaybesetautomatically(AutoBlanking)orspecifiedusingthesuppliedPC

software.

•MAC16N-1:16discreteopen-collectorNPN(currentsinking)transistoroutputs.

•MAC16P-1:16discreteopen-collectorPNP(currentsourcing)transistoroutputs.

6 P/N 43298 rev. E

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

System Overview

1.1.2 Sensing Response

Sensingresponseisafunctionofthenumberofbeamsinterrogated(i.e.,steps)per

scanofthearray.Thetimeperstepis55µs(0.000055seconds).Asaresult,dense

arrays(i.e.,3/8"beamspacing)yieldthehighestsensingresolution,whilearrayswith

wider(3/4")beamspacingofferfastersensingresponse.

1.1.4 Supplied System Software

Thesuppliedsoftwareprogram,usedtoconfigureeachSystemcontrolmodule,may

berunonanyPCrunningWindows®XP, Vista, or 7.Themenu-driven

programwalkstheuserthroughthemanyscanningandoutputoptions.Afterthe

desiredoptionsareselected,theusercansavethecombinationofselectionsina

ParameterSetupFile(PSF),andstoreitinthecontrolmodule’snon-volatilememory.

AnynumberofPSFsmaybestoredinthecomputerandrecalledasneeded.

Thesoftwarealsoprovidesalignmentanddiagnosticsroutines.AnAlignmentscreen

displaystheindividualstatusofeachbeaminthelightscreen,aswellasthetotal

numberofbeamsintheSystem,andtotalsofbeamsblocked,made,andblanked.

Built-insystemdiagnosticscanbeusedtoassessemitterandreceiverhardware

errors.

P/N 43298 rev. E 7

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

System Overview

1.2 System Components

1.2.1 Emitter and Receiver Models

Figure 1-3. MINI-ARRAY system components

Quick-Disconnect

Cables

DIN-Rail-Mountable

Control Module

User-Supplied PC

Configure and monitor the System

with the supplied software and

a PC-compatible computer (see

Section 1.1.4).

Emitter Receiver

1.2.2 Controller-to-Sensor Cables

2requiredpersystem

19.1 mm (3/4") beam spacing – 16 beams/foot

Emitter / Receiver

Models Array Length Total

Beams

BMEL616A / BMRL616A 133mm(5.25") 8

BMEL1216A / BMRL1216A 286mm(11.25") 16

BMEL1816A / BMRL1816A 438mm(17.25") 24

BMEL2416A / BMRL2416A 591mm(23.25") 32

BMEL3016A / BMRL3016A 743mm(29.25") 40

BMEL3616A / BMRL3616A 895mm(35.25") 48

BMEL4216A / BMRL4216A 1048mm(41.25") 56

BMEL4816A / BMRL4816A 1200mm(47.25") 64

BMEL6016A / BMRL6016A 1505mm(59.25") 80

BMEL7216A / BMRL7216A 1810mm(71.25") 96

9.5 mm (3/8") beam spacing – 32 beams/foot

BMEL632A / BMRL632A 143mm(5.62") 16

BMEL1232A / BMRL1232A 295mm(11.62") 32

BMEL1832A / BMRL1832A 448mm(17.62") 48

BMEL2432A / BMRL2432A 600mm(23.62") 64

BMEL3032A / BMRL3032A 752mm(29.62") 80

BMEL3632A / BMRL3632A 905mm(35.62") 96

BMEL4232A / BMRL4232A 1057mm(41.62") 112

BMEL4832A / BMRL4832A 1210mm(47.62") 128

BMEL6032A /BMRL6032A 1514mm(59.62") 160

BMEL7232A / BMRL7232A 1819mm(71.62") 192

Model Length QD Connector

QDC-515C 4.6m(15')

5-pinMini-style

straight

QDC-525C 7.6m(25')

QDC-550C 15.2m(50')

MAQDC-575C 22.7m(75')

MAQDC-5100C 30.3m(100')

MAQDC-5125C 37.9m(125')

MAQDC-5150C 45.5m(150')

8 P/N 43298 rev. E

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

DimensionsforallMACSeriesControllerslistedaboveare:110x100x75mm(4.3"x3.9"x3.0");seeFigure2-2.

*SeeSection5.5.3foradetaileddescriptionofavailablescananalysismodes.

System Overview

1.2.3 MINI-ARRAY MAC Series Controller Models

Controller

Model

Supply

Voltage Inputs Output 1 Output 2

Scan

Analysis

Modes*

PSF

Parameter

Diskette

Serial

Output

MAC-1

16to30Vdc 1SensorPair

1Gate

DiscreteReedRelay

DiscreteNPN

8 43989

RS-232

and

RS-485

MACN-1 DiscreteNPN

MACP-1 DiscretePNP DiscretePNP

MACV-1 (2)Analog

0to10VdcSourcing DiscreteNPN

RS-232

MACI-1 (2)Analog

4to20mASinking

MAC16N-1 16DiscreteNPNOutputs

10 59114

MAC16P-1 16DiscretePNPOutputs

P/N 43298 rev. E 9

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

Specifications

2. Specifications

2.1 Emitter and Receiver Specifications

Emitter/Receiver Range

9.5 mm (3/8") Beam Spacing

0.6to6.1m(2to20')forsensors<4'

0.6to4.6m(2to15')forsensors>4'

NOTE:Maximumrangeisspecifiedatthe

pointwhere3xexcessgainremains.

19.1 mm (3/4") Beam Spacing

0.9to17m(3to55')forsensors<4'

0.9to14m(3to45')forsensors>4'

NOTE:Maximumrangeisspecifiedatthepoint

where3xexcessgainremains.

Minimum Object Sensitivity

9.5 mm (3/8") Beam Spacing

19.1mm(0.75")

InterlacedMode:12.7mm(0.5")*

*NOTE:Assumessensingisinmiddle

one-thirdofscanningrange.

19.1 mm (3/4") Beam Spacing

38.1mm(1.5")

InterlacedMode:25.4mm(1.0")*

*NOTE:Assumessensingisinmiddle

one-thirdofscanningrange.

Sensor Scan Time 55microsecondsperbeam,plus1millisecondprocessingtimeperscan.(Assumesstraightscan,

continuousscan,andTBB mode;seeSection5.5.5ScanningModesforfurtherinformation.)

Power Requirements

Emitter

0.10amps@12Vdc

NOTE:Maximumcurrentisfora6'sensor.

Receiver

9.5mm(3/8")beams:0.75amps@12Vdcmax.

19.1mm(3/4")beams:0.50amps@12Vdcmax.

NOTE:Maximumcurrentisfora6'sensor.

Connections

Emitterandreceiverconnecttocontrollerusingtwo5-conductorquick-disconnectcables(one

eachforemitterandreceiver),orderedseparately.SeeSection1foravailablecablelengths.

Cablesmeasure8.1mm(0.32")dia.,andareshieldedandPVC-jacketed;conductorsare20-gauge.

•UseonlyBannercables,whichincorporatea"“twistedpair”fornoiseimmunityonRS-485data

communicationlines.

•Emitterandreceivercablesmaynotexceed250'each.

Status Indicators

(See Section 6.1 for more

information)

Emitter

RedLEDlightsforproperoperation

Receiver

Green:sensorsaligned(>3xexcessgain)

Yellow:marginalalignment(1x-3xexcessgain)

Red:sensorsmisalignedorbeam(s)blocked

Environmental Rating NEMA4,13(IECIP65)

Construction Aluminumhousingwithblackanodizedfinish;acryliclenscover

Operating Conditions Temperature: -20°to70°C(-4°to158°F)

Max. rel. humidity: 95%(non-condensing)

10 P/N 43298 rev. E

Banner Engineering Corp. •Minneapolis,MNU.S.A.

www.bannerengineering.com•Tel:763.544.3164

MINI-ARRAY®

InstructionManual

2.2 Emitter and Receiver Dimensions

Specifications

With mounting bracket flanges “out”

Figure 2-1. Emitter and receiver mounting dimensions and defined area location

With mounting bracket flanges “in”

18.3 mm

(0.72")

2.5 mm

(0.10")

38.1 mm Square

(1.50")

10.2 mm

(0.40")

(Distance to First

Optical Channel)

9.5 mm

(3/8")

Beam

Spacing

38.1mm

(1.50")

19.1 mm

(3/4")

Beam

Spacing

42.9mm

(1.69")

Emitter/Receiver Models Housing Length Distance Between Bracket Holes

L1 L2 L3

BMEL6..A / BMRL6..A 201.0mm(7.9") 233.9mm(9.21") 177.0mm(6.97")

BMEL12..A / BMRL12..A 356.0mm(14.0") 389.7mm(15.35") 332.8mm(13.1")

BMEL18..A / BMRL18..A 505.0mm(19.9") 538.7mm(21.22") 481.8mm(18.97")

BMEL24..A / BMRL24..A 659.0mm(26.0") 693.2mm(27.31") 636.3mm(25.05")

BMEL30..A / BMRL30.A 810.0mm(31.9") 843.5mm(33.23") 786.6mm(30.97")

BMEL36..A / BMRL36.A 963.0mm(37.9") 997.4mm(39.29") 940.5mm(37.0")

BMEL42..A / BMRL42.A 1115.0mm(43.9") 1148.0mm(45.2") 1091.0mm(43.0")

BMEL48..A / BMRL48.A 1267.0mm(49.9") 1301.0mm(51.2") 1244.0mm(49.0")

BMEL60..A / BMRL60..A 1572.0mm(61a.9") 1606.0mm(63.2") 1549.0mm(61.0")

BMEL72..A / BMRL72..A 1877.0mm(73.9") 1910.0mm(75.2") 1853.0mm(73.0")

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