Banner PresencePLUS P1B65Q User manual

Model P1B65Q
Pixel-Counting Sensor
Instruction Manual
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Contents
OVERVIEW
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM COMPONENTS
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lenses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Light Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SENSOR SETUP
Changing Lens Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting the Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Appropriate Sensing Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LIGHTING SETUP
Selecting a Light Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing the Fluorescent Ring Lamp . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing the LED Ring Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the Polarizing Filter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SENSOR OPERATION
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Programming and Monitoring the Sensor. . . . . . . . . . . . . . . . . . . . . . 14
Controller Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MAINTENANCE
Cleaning the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing the Light Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REFERENCE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AppendixA: Selecting a Lens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Appendix B: Component Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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OVERVIEW
The PresencePLUS™Pixel-Counting Sensor Model P1B65Q houses a
512 x 384 CMOS pixel array and a programmable microprocessor. The
sensor captures a gray-scale image, converts the image to binary format
based on adjustable gray-scale thresholds, counts the number of white or
black pixels, and judges the image as “PASS” or “FAIL” by comparing the
counts to reference counts.
An image is captured in response to a signal from a user-supplied trigger
input device. The trigger device is typically a presence-sensing device
such as a photoelectric sensor that delivers an input signal coincident with
the passage of the leading or trailing edge of an object to be inspected.
The binary value of each pixel is determined by two adjustable gray-scale
thresholds. The lower threshold defines the division between “light” and
“dark”. The sensor counts all light pixels as white and all dark pixels as
black. The upper threshold defines the limit above which pixels will be
ignored. The sensor may be set to count either black or white pixels and to
accept a percentage above or below reference pixel counts.
The remote PresencePLUS™Controller Model PRC1 is used to configure
trigger input, signal output, and lighting options and to program all other
sensor parameters. While the sensor is in operation, the controller may be
used to view captured images and monitor sensor performance.
For more information about programming and
operating the sensor, see page 14.
Gray-scale images are converted to black and white by comparing the value of each pixel to
adjustable gray-scale thresholds
Product Description
Gray-Scale Binary Upper
Threshold
Lower
Threshold
Ignorespixels with a valueabove
this threshold.
Counts pixels with a value below
this threshold as black.
Counts pixels with a value between
these thresholds as white.
255 (White)
0 (Black)
Application Examples
The PresencePLUS sensor is a solution to many
inspection applications where a defect can occur
anywhere within the sensor’s field of view, and where a
configuration of multiple discrete sensors is either cost-
prohibitive or mechanically impractical. The inspection
examples shown on the next page illustrate a few
application possibilities.
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Missing Date/Lot Code Inspection and
Print Quality Control
Controller LCD DisplayController LCD DisplayController LCD Display
OVERVIEW
3
0 ABC 123
EXP 7/02
0 ABC 123
EXP 7/02
0 ABC 123
EXP
0 ABC123
E
X
P
7
/
0
2
EjectWrong
Orientation
Missing Tablet Detection IC Orientation Inspection
Correct
Incorrect
SETUP
Focus
101
LIGHTEN
0
DARKEN
DONE
SETUP
Focus
84
LIGHTEN
0
DARKEN
DONE
SETUP
Focus
98
LIGHTEN
0
DARKEN
DONE
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SYSTEM COMPONENTS
Controller
The PresencePLUS Controller PRC1 is required
to configure and program the sensor and to
monitor sensor performance (see page 14).
Cables
Banner offers three 6-conductor quick-
disconnect cable choices:
•MQDC-606 2 m (6.5') long
•MQDC-615 5 m (15') long
•MQDC-630 9 m (30') long
Lenses
Banner offers three C-mount lens choices:
•LCF08 8 mm
•LCF12 12 mm
•LCF16 16 mm
The lens may be user-supplied. For information
about how to select a lens, see page 23.
Mounting Brackets
Banner offers two mounting bracket choices:
•SMBPBM Base-mounting bracket
•SMBPCM Column-mounting bracket
For bracket dimension details, see pages 20-21.
Light Sources
Banner offers two light source choices:
•HFFW5100 Fluorescent ring lamp
•LEDR140 Visible red LED ring lamp
The fluorescent ring lamp supplies the greater
amount of light. The LED ring lamp should be
reserved for high-contrast sensing applications.
Apolarizing lens kit, model LEDRPFK, is
available for the LED ring lamp, which makes it
the first choice when sensing at 90° to a shiny
surface.
The light source may be user-supplied. For
more information, see page 9.
Kits
Banner offers seven PresencePLUS kit choices
which include a P1B65Q sensor, PRC1
controller, MQDC-615 cable, bracket, and light
source. For kit details, see page 27.
The PresencePLUS Sensor P1B65Q requires several other components to create a working system: controller, cable, lens,
mounting bracket (if needed), light source, trigger device (user-supplied), and power supply (user-supplied).
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SYSTEM COMPONENTS
PresencePLUS Sensor
Model P1B65Q
PresencePLUS Controller
Model PRC1
Visible Red LED Ring Lamp
Model LEDR140
Polarizing Filter Kit
Model LEDRPFK
Column-Mounting Bracket
Model SMBPCM
Base-Mounting Bracket
Model SMBPBM
Mounting Bracket (select one):
Light Source (select one):
POWERREADY
FAULT
PASS
FAIL
Trigger
Device
24V dc
Supply
Output 1
Output 2
Output 3
C-Mount Lens (select one):
16 mm
Model LCF16
12 mm
Model LCF12
8 mm
Model LCF08
Fluorescent Ring Lamp
Model HFFW5100
Quick-Disconnect Cable (select one):
Model MQDC-606 (2 m)
Model MQDC-615 (5 m)
Model MQDC-630 (9 m)
Coil Cord
(supplied with PRC1)
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SENSOR SETUP
Changing Lens Filters
The lens filter is located behind the lens, held in
place with a retainer ring.
To add or remove a filter, use the tool supplied
with the sensor to remove and replace the
retainer ring.
Ared filter is pre-installed in each sensor for use
with the LED light source LEDR140. Remove
this red filter if using the fluorescent ring lamp
HFFW5100 or other white light source.
When using the polarizing kit LEDRPFK, install
the polarizing filter on top of the red filter (see
page 12).
NOTE: When using more than one filter, the
order of the filters will not affect performance.
Mounting the Lens
Remove the protective cover from the sensor.
Remove the two protective covers from the lens.
Install the lens onto the sensor by gripping the
silver lens base and turning clockwise (RH
thread).
NOTE: Do not install by gripping and turning the
plastic lens shroud.Also, see CAUTION, below.
After focusing the lens, use the suppliedAllen
wrench to lock the lens by clockwise rotation
(RH thread), finger tight, in the three set screws
on the base of the lens.
Appropriate Sensing Environment
The sensing location must meet the following
criteria for reliable operation:
• Stable ambient temperature: 0 to 50°C
(+32 to 122°F)
• Ambient relative humidity: 35 to 90%,
non-condensing
• Stable ambient lighting: no large, quick
changes in light level; no direct or reflected
sunlight
• No significant vibration or mechanical
shock
• No liquid splash
• No contact with corrosive or volatile
materials or atmosphere
• Minimal dust or dirt
Retainer Ring Tool
Grip Silver lens base
Do not grip plastic lens shroud
CAUTION . . .
Avoid damage to sensor caused
by electrostatic discharge (ESD).
Use a properly-connected ESD wrist
strap or other proven method for
preventing electrostatic discharges
when installing a lens or attaching a
cable.
!
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Column-Mounting Bracket SMBPCM Base-Mounting Bracket SMBPBM
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SENSOR SETUP
The P1B65Q sensor has ten M4 x 0.7 tapped
holes: four on each side and two on the base.
The sensor is supplied with four M4 sockethead
cap screws, washers, and lockwashers, and a
3 mmAllen wrench.
The sensor may be secured to a Banner-
supplied mounting bracket, or to any flat surface
up to 2.0 mm (0.08") thick.
For dimensional details of the sensor and
brackets, see pages 19-21.
Mounting the Sensor
P1B65Q
SMBPBM
Secure with two M4 sockethead cap
screws,washers, and lockwashers
supplied with sensor
(Either Direction)
1/4" - 20
Thread
M6 x 1
Thread
P1B65Q
SMBPCM Secure with four M4 Phillips
flathead screws supplied with
bracket (two on each side)
Securing to Mounting Brackets
Banner offers two mounting bracket choices:
• Column-mounting bracket SMBPCM
• Base-mounting bracket SMBPBM
Secure the sensor to the column-mounting
bracket with the four M4 Phillips flathead screws
supplied with the bracket (two on each side).
Secure the sensor to the base-mounting
bracket with two of the M4 sockethead cap
screws, washers, and lockwashers supplied
with the sensor.
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SENSOR SETUP
Connecting Cables
Before connecting cables, be sure the power supply is OFF. See CAUTION on page 6. For
complete sensor specifications and hookup diagrams, see pages 17-18.
Power
The power source is user-supplied.
Alone, the sensor requires 22 to 26V dc; with
a maximum current of 250 mA(exclusive of
loads and the current required by the PRC1
controller and optional LEDR140 light
source).
Using the PRC1 controller, the maximum
current is 450 mA. Using the LEDR140 light
source, the maximum current is 550 mA.
Using both, the maximum current is 750 mA.
Connect the Brown wire of the sensor cable
(MQDC-6 Series) to +V and the Blue wire to
dc common.Attach the connector end of the
cable to the sensor.
Controller
Acoiled cord with modular plugs is supplied
with the PRC1 controller.
Insert one plug into the controller and the
other plug into the sensor. Be sure the plugs
click into place.
Trigger Input
Connect the Pink wire of the sensor cable to
the user-supplied trigger device.
The default trigger input setting accepts
signals from a trigger device with an NPN
(current sinking) output. If the trigger device
output is PNP (current sourcing), use the
PRC1 controller to reconfigure the sensor.
Signal Output
The sensor provides three SPST solid-state
contacts which may be individually
programmed for either NPN (current sinking)
or PNP (current sourcing). Each output is
capable of switching up to 26V dc max at
50 mAmax. Outputs are protected against
continuous overload or short circuit.
Note: Output loads must not be returned to
any voltage greater than +V.
Configure the sensor cable output wires as
follows: White = Output #1, Black = Output
#2, Gray = Output #3. Use the PRC1
controller to set sensor output parameters.
P1B65Q
PRC1
MQDC-6 Series
Cable
Coiled Cord
(Supplied with PRC1)
To Power Source,
Trigger Device,and
Output Receivers
Controller
SETUP ROI TEACH
LOAD
HELP ENTER
RUN
MAIN RUN P/F RUN JUDGE
CONFIG MAIN
MENU IMAGE CNTRL
TM
Controller Connection to the Sensor
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CAUTION
Avoid
sensor damage
caused by ESD see
page 6.
!
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