Banner Expert DF-G1-NS-2M User manual

Installation Guide
Advanced sensor with dual digital displays for use with plastic and glass fiber optic assemblies.
For complete technical information about this product, including dimensions, accessories, and specifications, see http://
www.bannerengineering.com and search 161999.
Overview
Figure 1. DF-G1 Model Features
1Output LED
2LO/DO Switch
3RUN/PRG/ADJ Mode Switch
4Lever Action Fiber Clamp
5Red Signal Level
6Green Threshold
7+/SET/- Rocker Button
WARNING: Not To Be Used for Personnel Protection
Never use this device as a sensing device for personnel protection. Doing so could lead to
serious injury or death. This device does not include the self-checking redundant circuitry necessary
to allow its use in personnel safety applications. A sensor failure or malfunction can cause either an
energized or de-energized sensor output condition.
Models
Model Outputs Connector1
DF-G1-NS-2M Single NPN
2 m (6.5 ft) cable, 4-wire
DF-G1-PS-2M Single PNP
DF-G1-KS-2M Dual outputs, 1 push-pull IO-Link and 1
PNP (complementary outputs)
DF-G1-NS-Q5 Single NPN
150 mm (6 in) PVC pigtail, M12 Euro QD connector,
4-pin
DF-G1-PS-Q5 Single PNP
DF-G1-KS-Q5 Dual outputs, 1 push-pull IO-Link and 1
PNP (complementary outputs)
DF-G1-NS-Q7 Single NPN
Integral M8 Pico QD connector, 4-pin
DF-G1-PS-Q7 Single PNP
DF-G1-KS-Q7 Dual outputs, 1 push-pull IO-Link and 1
PNP (complementary outputs)
1Connector options:
•A model with a QD connector requires a mating cordset .
• For 9 m cable, change the suffix 2M to 9M in the 2 m model number (example, DF-G1-NS-9M).
• For 150 mm (6 in) PVC pigtail, M8 Pico QD connector, 4-pin change the suffix 2M to Q3 in the 2 m model number (example, DF-G1-NS-Q3).
DF-G1 Expert™Dual Display Fiber Amplifier
Original Document
161275 Rev. D 9 September 2015
161275

Installation Instructions
Mounting Instructions
Mount on a DIN Rail
1. Hook the DIN rail clip on the bottom of the DF-G1
over the edge of the DIN rail (1).
2. Push the DF-G1 up on the DIN rail (1).
3. Pivot the DF-G1 onto the DIN rail, pressing until it
snaps into place (2).
Mount to the Accessory Bracket
1. Position the DF-G1 in the SA-DIN-BRACKET.
2. Insert the supplied M3 screws.
3. Tighten the screws.
Remove from a DIN rail
1. Push the DF-G1 up on the DIN rail (1).
2. Pivot the DF-G1 away from the DIN rail and remove
it (2).
Installing the Fibers
Follow these steps to install glass or plastic fibers.
1. Open the dust cover.
2. Move the fiber clamp forward to unlock it.
3. Insert the fiber(s) into the fiber port(s) until they
stop.
4. Move the fiber clamp backward to lock the fiber(s).
5. Close the dust cover.
Fiber Emitter
Port
Fiber Receiver
Fiber Clamp
Port
Move forward
to release the
fibers
Fiber Adapters
NOTE: If a thin fiber with less than 2.2 mm outer diameter is used, install the fiber adapter provided
with the fiber assembly to ensure a reliable fit in the fiber holder. Banner includes the adapters with all
fiber assemblies.
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2 www.bannerengineering.com - Tel: [phone] P/N 161275 Rev. D

TO
FIBERS
TO
SENSOR
Fiber Outer Diameter (mm) Adapter Color
Ø 1.0 Black
Ø 1.3 Red
Ø 2.2 No adapter needed
When connecting coaxial-type fiber assemblies to the amplifier, install the single-core fiber to the Transmitter port, and the
multi-core fiber to the Receiver port. This will result in the most reliable detection.
TRANSMITTER
RECEIVER
Single-core fiber
Multi-core fiber
Wiring Diagrams
NPN Models
Remote
Programming
(N.O.)
10-30V dc
Load
PNP Models
Load
10–30 V dc
Remote
Programming
(N.O.)
Key
1 = Brown
2 = White
3 = Blue
4 = Black
IO-Link Models
(C/Q)
(Q)
PUSH-PULL
18-30V dc
Load
Load
NOTE: Open lead wires must be connected to a terminal block.
DF-G1 Expert™Dual Display Fiber Amplifier
P/N 161275 Rev. D www.bannerengineering.com - Tel: [phone]

Top Panel Interface
Opening the dust cover provides access to the top panel interface. The top panel interface consists of the RUN/PRG/ADJ
mode switch, LO/DO switch, +/SET/- rocker button, dual red/green digital displays, and output LED.
RUN/PRG/ADJ Mode Switch
The RUN/PRG/ADJ mode switch puts the sensor in RUN, PRG (Program), or ADJ (Adjust) mode. RUN
mode allows the sensor to operate normally and prevents unintentional programming changes via the
+/SET/- rocker button. PRG mode allows the sensor to be programmed through the display-driven
programming menu (see Program Mode below). ADJ mode allows the user to perform Expert
TEACH/SET methods and Manual Adjust (see Adjust Mode below).
LO/DO Switch
The LO/DO switch selects Light Operate or Dark Operate mode. In Light Operate mode, the output is
ON when the sensing condition is above the threshold. (For Window SET, the output is ON when the
sensing condition is inside the window.) In Dark Operate mode, the output is ON when the sensing
condition is below the threshold. (For Window SET, the output is ON when the sensing condition is
outside the window.)
+/SET/- Rocker Button
The +/SET/- rocker button is a 3-way button. The +/- positions are engaged by rocking the button left/
right. The SET position is engaged by clicking down the button while the rocker is in the middle position.
All three button positions are used during PRG mode to navigate the display-driven programming menu.
During ADJ mode, SET is used to perform TEACH/SET methods and +/- are used to manually adjust the
threshold(s). The rocker button is disabled during RUN mode, except when using Window SET, see
Window SET on page 7.
Red/Green Digital Displays
During RUN and ADJ modes, the Red display shows the signal level, and the Green display shows the
threshold. During PRG mode, both displays are used to navigate the display-driven programming menu.
Output LED
The output LED provides a visible indication when the output is activated.
Operating Instructions
Remote Input/IO-Link
For more information about how to perform TEACH/SET methods, to program the sensor remotely, or to interface with the
sensor via IO-Link, see the DF-G1 Manual (P/N 161999).
Run Mode
Run mode allows the sensor to operate normally and prevents unintentional programming changes. The +/SET/- rocker
button is disabled during RUN mode, except when using Window SET, see Window SET on page 7.
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Program Mode
Program (PRG) mode allows the
following settings to be
programmed in the DF-G1:
Factory Default Settings:
Setting Factory
Default
Threshold 2026
TEACH
Selection Two-Point TEACH
Response
Speed Standard - 500 µs
Offset Percent 10%
Auto
Thresholds OFF
OFF Delay 0 (Disabled)
OFF One-Shot 0 (Disabled)
ON Delay 0 (Disabled)
ON One-Shot 0 (Disabled)
Display
Readout Numeric, ECO disabled,
Normal
Orientation
Gain Selection Auto Gain
2Pt tcH
tcH SEL
Lt SEt
dr SEt
CAL SEt
wind SEt
dYn tcH
diSP 1234
diSP rEAd
Auto GAin
GAin SEL
1234 Gn 1 1234 Gn 2
no
FctY dEF
yES
rESP SPd
500 uS
2000 uS
5000 uS
200 uS
OFSt Pct
10 Pct
min OFSt
Auto thr
On
999 Pct
oFF
OFF dLY
0 ms
9999 ms
(+) or (-)
to set value
(+) or (-)
to set value
OFF 1Sho
0 ms
9999 ms
(+) or (-)
to set value
On dLY
0 ms
9999 ms
(+) or (-)
to set value
On 1Sho
0 ms
9999 ms
(+) or (-)
to set value
diSP 123P
Eco 1234
Eco 123P
diSP 1234
diSP 123P
Eco 1234
Eco 123P
(display flips 180˚)
1234 Gn 8
Fixed Gain Set
To scroll through menu lists: Press “+” or “-” To enter a choice list or to select and save: Click SET
To exit a choice list without saving: Press and hold SET for 2 seconds
Click SET
to enter choice list
Press and hold SET to exit
choice list without saving
DISPLAY
LOOP
Return to Menu List
PROGRAM MODE
Mode Switch
to “PRG”
Click SET
to enter choice list
DISPLAY
LOOP
Click SET
to enter choice list
Click SET
to enter choice list
DISPLAY
LOOP
Click SET
to enter choice list
Click SET
to enter choice list
Click SET
to enter choice list
Click SET
to enter choice list
Click SET
to enter choice list
DISPLAY
LOOP
Click SET
to enter choice list
DISPLAY
LOOP
Click SET
to enter choice list
DISPLAY
LOOP
+-
SET
rocker button
Click SET to select and save a choice in any list
Menu
List
on display represents a “w” on display represents a “m”
DF-G1 Expert™Dual Display Fiber Amplifier
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Adjust Mode
Sliding the RUN/PRG/ADJ mode switch to the ADJ position allows the user to perform Expert TEACH/SET methods and
Manual Adjustment of the threshold(s).
TEACH Procedures
The instruction manual has detailed instructions for these TEACH modes:
•Two-Point TEACH
• Dynamic TEACH
• Window SET
• Light SET
• Dark SET
• Calibration SET
Two-Point TEACH
• Establishes a single switching threshold
• Threshold can be adjusted by using the "+" and "-" rocker button (Manual Adjust)
Two-Point TEACH is used when two conditions can be presented statically to the sensor. The sensor locates a single
sensing threshold (the switch point) midway between the two taught conditions, with the Output ON condition on one side,
and the Output OFF condition on the other.
Sensor positions
threshold midway
between taught conditions
Darkest
(no signal)
Most Light
(saturated
signal)
Output OFF Output ON
Darkest Taught
Condition
Lightest Taught
Condition
Position
adjusted by
Manual Adjust
Figure 2. Two-Point TEACH (Light Operate shown)
The Output ON and OFF conditions can be reversed by using the LO/DO (Light Operate/ Dark Operate) switch.
Dynamic TEACH
•Teaches on-the-fly
• Establishes a single switching threshold
• Threshold can be adjusted using "+" and "-" rocker button (Manual Adjust)
Dynamic TEACH is best used when a machine or process may not be stopped for teaching. The sensor learns during actual
sensing conditions, taking multiple samples of the light and dark conditions and automatically setting the threshold at the
optimum level.
Sensor positions
threshold midway
between taught conditions
Darkest
(no signal)
Most Light
(saturated
signal)
Output OFF Output ON
Darkest Taught
Condition
Lightest Taught
Condition
Position
adjusted by
Manual Adjust
Figure 3. Dynamic TEACH (Light Operate shown)
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The output ON and OFF conditions can be reversed using the LO/DO switch.
Window SET
•Sets window thresholds that extend a programmable % offset above and below the presented condition
• All other conditions (lighter or darker) cause the output to change state
• Sensing window center can be adjusted using "+" and "-" rocker button (Manual Adjust)
• Recommended for applications where a product may not always appear in the same place, or when other signals
may appear
• See Program Mode in the user's manual for programming the Offset Percent setting (to increase/decrease the
window size)
A single sensing condition is presented, and the sensor positions window thresholds a programmable % offset above and
below the presented condition. In LO mode, Window SET designates a sensing window with the Output ON condition inside
the window, and the Output OFF conditions outside the window.
Sensor positions
window thresholds
a programmable %
offset from the
presented condition
Darkest
(no signal)
Most Light
(saturated
signal)
Condition
Presented
Sensing window
center adjusted by
Manual Adjust
Output OFF Output OFFOutput ON
Figure 4. Window SET (Light Operate shown)
Output ON and OFF conditions can be reversed using the LO/DO switch.
Light SET
•Sets a threshold a programmable % offset below the presented condition
• Changes output state on any condition darker than the threshold condition
• Threshold can be adjusted using "+" and "-" rocker button (Manual Adjust)
• Recommended for applications where only one condition is known, for example a stable light background with
varying darker targets
• See Program Mode on page 5 for programming the Offset Percent setting
A single sensing condition is presented, and the sensor positions a threshold a programmable % offset below the
presented condition. When a condition darker than the threshold is sensed, the output either turns ON or OFF, depending
on the LO/DO setting.
Threshold position
adjusted by
Manual Adjust
Sensor positions
threshold a programmable
% offset below the
presented condition
Darkest
(no signal)
Most Light
(saturated
signal)
Output OFF Output ON
Condition
Presented
Figure 5. Light SET (Light Operate shown)
Dark SET
•Sets a threshold a programmable % offset above the presented condition
• Any condition lighter than the threshold condition causes the output to change state
• Threshold can be adjusted using "+" and "-" rocker button (Manual Adjust)
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• Recommended for applications where only one condition is known, for example a stable dark background with
varying lighter targets
•See Program Mode on page 5 for programming the Offset Percent setting
NOTE: Offset Percent MUST be programmed to Minimum Offset to accept conditions of no signal (0
counts).
A single sensing condition is presented, and the sensor positions a threshold a programmable % offset above the
presented condition. When a condition lighter than the threshold is sensed, the output either turns ON or OFF, depending
on the LO/DO setting.
Sensor positions
threshold a programmable
% offset above the
presented condition
Threshold position
adjusted by
Manual Adjust
Darkest
(no signal)
Most Light
(saturated
signal)
Output OFF Output ON
Condition
Presented
Figure 6. Dark SET (Light Operate shown)
Calibration SET
•Sets a threshold exactly at the presented condition
• Threshold can be adjusted using "+" and "-" rocker button (Manual Adjust)
A single sensing condition is presented, and the sensor positions a threshold exactly at the presented condition. When a
condition lighter than the threshold is sensed, the output either turns ON or OFF, depending on the LO/DO setting.
Sensor positions
threshold exactly at
the presented condition
Threshold position
adjusted by
Manual Adjust
Darkest
(no signal)
Most Light
(saturated
signal)
Output OFF Output ON
Condition
Presented
Figure 7. Calibration SET (Light Operate shown)
Troubleshooting
Manual Adjustments Disabled
Manual adjustments are disabled when Auto Thresholds are ON. If a manual adjustment is attempted while Auto
Thresholds are ON, the Green display will flash .
Percent Minimum Difference after TEACH
The Two-Point and Dynamic TEACH methods will flash a % minimum difference on the displays after a PASS or FAIL.
Value PASS/FAIL Description
0 to 99% FAIL The difference of the taught conditions does not meet the required minimum
100 to 300% PASS The difference of the taught conditions just meets/exceeds the required minimum,
minor sensing variables may affect sensing reliability
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Value PASS/FAIL Description
300 to 600% PASS The difference of the taught conditions sufficiently exceeds the required minimum,
minor sensing variables will not affect sensing reliability
600% + PASS The difference of the taught conditions greatly exceeds the required minimum, very
stable operation
Percent Offset after SET
The Window, Dark, and Light SET methods will flash a % offset on the displays after a PASS or FAIL.
SET Result % Offset Meaning
PASS (with % Offset) Displays the % offset used for the SET method
FAIL (with % Offset) Displays the minimum required % offset necessary to PASS the SET method
FAIL (without % Offset) Presented condition cannot be used for the SET method
Threshold Alert or Threshold Error
Severe contamination/changes in the taught condition can prevent the Auto Thresholds algorithm from optimizing the
threshold(s).
State Display Description Corrective Action
Threshold Alert Alternates
and
The threshold(s) cannot be
optimized, but the sensor's output
will still continue to function
Cleaning/correcting the sensing
environment and/or a re-teach of the
sensor is highly recommended
Threshold Error The threshold(s) cannot be
optimized, and the sensor's output
will stop functioning
Cleaning/correcting the sensing
environment and/or a re-teach of the
sensor is required
DF-G1 Expert™Dual Display Fiber Amplifier
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Specifications
Sensing Beam
660 nm visible red
Supply Voltage
NPN/PNP models: 10 to 30 V dc Class 2 (10% maximum ripple)
IO-Link models: 18 to 30 V dc (10% maximum ripple)
Power and Current Consumption (exclusive of load)
Standard display mode: 960 mW, Current consumption < 40 mA at
24 V dc
ECO display mode: 720 mW, Current consumption < 30 mA at 24 V
dc
Supply Protection Circuitry
Protected against reverse polarity and transient overvoltages
Delay at Power-Up
500 milliseconds maximum; outputs do not conduct during this time
Output Configuration
NPN/PNP models: 1 current sinking (NPN) or 1 current sourcing
(PNP) output, depending on model
IO-Link models: 1 push-pull and 1 PNP (complementary outputs)
Required Overcurrent Protection
WARNING: Electrical connections must be
made by qualified personnel in accordance
with local and national electrical codes and
regulations.
Overcurrent protection is required to be provided by end product
application per the supplied table.
Overcurrent protection may be provided with external fusing or via
Current Limiting, Class 2 Power Supply.
Supply wiring leads < 24 AWG shall not be spliced.
For additional product support, go to http://
www.bannerengineering.com.
Supply Wiring Required Overcurrent Protection
20 5.0 Amps
22 3.0 Amps
24 2.0 Amps
26 1.0 Amps
28 0.8 Amps
30 0.5 Amps
Output Rating
100 mA maximum load (derate 1 mA per °C above 30 °C)
OFF-state leakage current: NPN/PNP models: < 5 μA at 30 V dc;
IO-Link models: < 50 μA at 30 V dc
ON-state saturation voltage: NPN: < 1.5 V; PNP /IO-Link: < 2 V
Output Protection
Protected against output short-circuit, continuous overload, transient
overvoltages, and false pulse on power-up
Output Response Time
High Speed: 200 µs; Standard: 500 µs; Long Range: 2 ms; Extra Long
Range: 5 ms
Repeatability
High Speed: 66 µs, Standard/Long Range/Extra Long Range: 100 µs
Construction
Black ABS/polycarbonate alloy (UL94 V-0 rated) housing, clear
polycarbonate cover
Connections
PVC-jacketed 2 m or 9 m (6.5 ft. or 30 ft.) 4-wire integral cable; or
integral 4-pin M8/Pico-style quick disconnect; or 150 mm (6 in.) cable
with a 4-pin M12/Euro-style quick disconnect; or 150 mm (6 in.) cable
with a 4-pin M8/Pico-style quick disconnect.
Environmental Rating
IEC IP50, NEMA 1
Operating Conditions
Temperature: −10 °C to +55 °C (+14 °F to +131 °F)
Storage Temperature: −20 °C to +85 °C (−4 °F to +185 °F)
Humidity: 90% at +60 °C maximum relative humidity (non-
condensing)
IO-Link Interface
Supports Smart Sensor Profile: Yes
Baud Rate: 38,400 bps (COM2)
Process Data Width: 16 bits
IODD files: Provide all programming options of top panel interface,
plus additional functionality, see the DF-G1 Manual (P/N 161999)
Certifications
Industrial
Control
Equipment
3TJJ
Banner Engineering Corp Limited Warranty
Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following
the date of shipment. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture
which, at the time it is returned to the factory, is found to have been defective during the warranty period. This warranty
does not cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR
IMPLIED (INCLUDING, WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE, COURSE OF DEALING OR
TRADE USAGE.
This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO
EVENT SHALL BANNER ENGINEERING CORP. BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR
ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL, CONSEQUENTIAL OR
SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE
PRODUCT, WHETHER ARISING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY,
NEGLIGENCE, OR OTHERWISE.
Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any
obligations or liabilities relating to any product previously manufactured by Banner Engineering Corp.
DF-G1 Expert™Dual Display Fiber Amplifier
www.bannerengineering.com - Tel: [phone]