Banner A-GAGE MINI-ARRAY MAC Series User manual

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
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
15
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”
L2
L1
X
18.3 mm
(0.72")
2.5 mm
(0.10")
38.1 mm Square
(1.50")
10.2 mm
(0.40")
L3
X
(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")