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")

P/N 43298 rev. E 11
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
2.3 Controller Specifications
Specifications
Power Requirements 16to30Vdc@1.25ampsmax.(seecurrentrequirementsforsensors);
Controlleralone(withoutsensorsconnected)requires0.1amp.
Inputs MINI-ARRAYsensorinput(5connections);emitterandreceiverwireinparalleltofive
terminals.
GATEinput:Optically-isolated,requires10to30Vdc(7.5Kinputimpedance)forgatesignal.
System Response Time Outputsarenotactivefor5secondsaftersystempowerup.Maximumresponsetimeforthe
discreteoutputsistwoscancycles.Ascancycleincludesasensorscanplusanyserialdata
transmission.
Serialtransmission(ifactivated)followseverysensorscan.
Discrete Outputs MAC-1: Output1(OUT1):Reedrelaycontactrated125Vac/dcmax.,10VAmax.resistive
load(non-inductive).
Output2(ALARM):OpencollectorNPNtransistorrated30Vdcmax.,150mAmax,
short-circuitprotected(maybeconfiguredasaseconddataanalysisoutput,system
alarmoutput,orscantriggeroutputforaparallelarray).
OFF-STATELeakageCurrent:<10µA@30Vdc
ON-STATESaturationVoltage:<1Volt@10mA,<1.5Volt@150mA
MACN-1: (2)OpencollectorNPNtransistoroutputs.
MACP-1:(2)OpencollectorPNPtransistoroutputs.
Transistorrated30Vdcmax.,150mAmax,shortcircuitprotected(maybe
configuredasaseconddataanalysisoutput,systemalarmoutput,orscantrigger
outputforaparallelarray).
OFF-STATELeakageCurrent<10µA@30Vdc
ON-STATESaturationVoltage<1Volt@10mA,<1.5Volt@150mA
MACV-1/MACI-1:Alarm:OpencollectorNPNtransistorrated30Vdcmax.150mAmax,short
circuitprotected.
(maybeconfiguredasadataanalysisoutput,systemalarmoutput,orscan
triggeroutputforaparallelarray)
OFF-STATELeakageCurrent:<10µA@30Vdc
ON-STATESaturationVoltage:<1Volt@10mA,<1.5Volt@150mA
MAC16P-1:SixteenopencollectorPNPtransistoroutputs.
MAC16N-1: SixteenopencollectorNPNtransistoroutputs.
30Vdcmax,150mAmax.,shortcircuitprotected.
OFF-STATEleakagecurrent:<10µA
ON-STATESaturationVoltage:<1Volt@10mA;<1.9V@150mA
Analog Outputs MACV-1: (2) 0-10VoltssourcingadjustableNullandSpan(20mAcurrentlimit).
MACI-1: (2)4-20mAcurrentsinkingadjustableNullandSpan(16to30Vinput).
Resolution:SpanminusNull,dividedbythenumberofsensorchannels
Linearity:0.1%ofFullScale
Temp. Var.: 0.01%ofFullScale/°C
Serial Data Outputs All Models: RS-232,ASCIIorbinarydataformat.
Baudrate:9600,19.2K,or38.4K8databits,1startbit,1stopbit,evenparity.
Cleardatamaybesuppressed;headerstringmaybesuppressedinbinary
format.
MAC-1, MACN-1,
and MACP-1: Upto15ControllersmaybegivenuniqueaddressforRS-485partyline.
Controller Programming ViaRS-232toPC-compatiblecomputerrunningWindows®.XP, Vista, or 7
operatingsystemandusingBanner-suppliedsoftware(seeusermanual).

12 P/N 43298 rev. E
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
Status Indicators
(See Section 6.2 for
more information)
The following status LEDs are located on the front panel:
OUTPUT1(red)(nameandfunctionvarydependingonmodel):Indicatesactiveoutput
ALARM(red):IndicatesthatOutput2or16isactive(dependingonmodel)
GATE(red):IndicatesvoltageisappliedtoGATEinput
ALIGN(green):Indicatessensoraligned(excessgain>1x)
Plus three diagnostic LEDs:
DIAG1(green):Indicatespowerisappliedtothemodule
DIAG2(red):Indicatesreceiverfailure
DIAG3(red):Indicatesemitterfailure
Sensor Scan Time For all models: 55microsecondsperbeamplusprocessingtime.
Theprocessingtimeisdependentonthescananalysisandthenumberofactiveoutputs.
Thistimingassumesastraightscan,continuous,andTBBmode.
MAC-1, MACN-1 & MACP-1:1millisecondprocessingtime.
MACV-1 & MACI-1:1.5millisecondsprocessingtime.
MAC16N-1 & MAC16P-1:2.3to7millisecondsprocessingtime.
Construction Polycarbonate
Environmental Rating NEMA1(IP20)
Operating Conditions Temperature:-20°to+70°C(-4°to+158°F)
Maximum Relative Humidity:95%(non-condensing)
2.4 Controller Dimensions
Figure 2-2. Control module dimensions and mounting hole locations
75.0 mm
(2.95")
60.8 mm
(2.40")
7.1 mm
(0.28")
Din mounting tab
(supplied)
Slot for screws (2)
M3.5 x 0.6 mm (2)
35.0 mm
(1.38")
Din mounting slot
100.0 mm
3.94"
85.3 mm
3.36"
7.4 mm
(0.29")
110.0 mm
(4.33")
Combo Head (Phillips/Slotted Screws
M3.5 x 0.6 mm x 14 mm (2 ) (#6 x 0.5" equivalent) (supplied)
M3.5 Washers (2) (#6 equivalent) (supplied)
M3.5 mm x 0.6 mm Nuts (2) (#6 equivalent) (supplied)
Recommended torque is
16-20 in -lbs on mounting screws
Specifications
2.3 Controller Specifications (continued)

P/N 43298 rev. E 13
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
Installation and Mechanical Alignment
3.1 Emitter and Receiver Mounting
BannerMINI-ARRAYemittersandreceiversaresmall,lightweight,andeasytomount;themountingbrackets(supplied)allow±30
degreesrotation.
Fromacommonpointofreference,makemeasurementstopositiontheemitterandreceiverinthesameplanewiththeir
midpointsdirectlyoppositeeachother.MounttheemitterandreceiverbracketsusingtheM4x0.7x14mmboltsandassociated
mountinghardware(allsupplied).SeeFigure3-1.
Althoughtheinternalcircuitryoftheemitterandreceivercanwithstandheavyimpulseforces,vibrationisolatorscanbeused
insteadoftheM4boltstodampenimpulseforcesandpreventpossibledamagefromresonantvibrationoftheemitterorreceiver
assembly.TwodifferentAnti-VibrationMountingKitsareavailablefromBannerasaccessories.
Figure 3-1. MINI-ARRAY emitter and receiver mounting hardware
Emitter
or
Receiver
Mounting
Mounting
Bracket
Surface
M4
Nut (4)
Washer (2)
with Compression
Slotted Hex Head
M4 x 10 mm
Bracket
Mounting
Nut
Washer
M4 x 14 mm
Screw with Flat
Washer
Compression
Washer (4)
Torque to
12 in. lbs.
(1.3 N-m)
3. Installation and Mechanical Alignment
P/N48955consistsof4anti-vibration
mounts(M4x0.7x9.5mm)and8
M4Kepsnuts.Thesemountsaremade
fromBUNA-Nrubberandaremore
resistanttochemicalsandoils.
P/N12847consistsof4anti-vibration
mounts(M4x0.7x9.5mm)and8
M4Kepsnuts.Thesemountsaremade
fromnaturalrubber,whichareless
chemicallyresistantthanthe48955
mounts,buthaveagreatersheerforce
specathighertemperature.

14 P/N 43298 rev. E
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
Installation and Mechanical Alignment
Figure 3-2. MINI-ARRAY emitter and receiver mounting bracket dimensions
Mounttheemitterandreceiverintheirmountingbrackets(showninFigure3-1),
andpositiontheredlensesofthetwounitsdirectlyfacingeachother.Theconnector
endsofbothsensorsmustpointinthesamedirection.Measurefromoneormore
referenceplanes(i.e.,thefloor)tothesamepointsontheemitterandreceiverto
verifytheirmechanicalalignment.Ifthesensorsarepositionedexactlyverticalor
exactlyhorizontal,acarpenter’slevelmaybeusefulforcheckingalignment.Extending
astraight-edgeorastringbetweenthesensorsmayhelpwithpositioning.Alsocheck
byeyeforline-of-sightalignment.Makeanynecessaryfinalmechanicaladjustments,
andhand-tightenthebrackethardware.SeeSection5forinformationonalignment
indicatorsandtheuseofthealignmentsoftwaresuppliedwiththecontroller.
Connecttheshieldedcablestotheemitterandreceiver,androutethemtothe
controllerlocation.Followthelocalwiringcodeforlow-voltagedccontrolcables.The
samecabletypeisusedforbothemitterandreceiver(twocablesrequiredpersystem).
Cutthecablestolengthaftermakingsuretheyareroutedproperly.Removecablebraid
atthecontrollerconnectionpoints(seeFigure3-4).
3.2 Controller Mounting
ThecontrollermustbeinstalledinsideanenclosurewithaNEMA(orIEC)rating
suitablefortheoperatingenvironment.
MountingdimensionsforthecontrollerareshowninFigure2-2.Thecontrolleris
suppliedwithM3.5x0.6hardwarefordirectmountingtoasurface,oritcanbe
mountedontostandard35mmDINrail.
3.3 Emitter and Receiver Hookups
Emitterandreceivercablesconnectinparalleltocontrollerterminals#4through#8.
Connectthewiresfrombothsensorcables,asfollows:
  Terminal4 Brown
  Terminal5 Blue
  Terminal6 Bare
  Terminal7 Black
  Terminal8 White
Trimoffthefoilshieldandthebraidedshieldatthepointwherethewiresexitthecable
(seeFigure3-4).
The“drainwire”istheuninsulatedstranded
wirewhichrunsbetweenthebraidedshield
andthefoilshield.Removethefoilshield
andbraidedshieldatthepointwherethe
wiresexitthecable.
Figure 3-4. Emitter/receiver cable
preparation
Tr im braided shield flush
with cable
Tr im foil shield flush
with cable
Uninsulated
drain wire
Emitter or
Receiver
8.1 mm
(0.32") max.
0.5" (13 mm) radius minimum bend
71 mm
2.8"
Figure 3-3. Quick-disconnect cable
clearances

P/N 43298 rev. E 15
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
Installation and Mechanical Alignment
Figure 3-5. Model MAC-1 hookup
1
+
–+ –
10-30V dc
Gate
16-30V dc
1.2 A Max.
234
5678
9
101112131415
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
V– V+
RS485
500 mA
Max.
Out 1
30V
150 mA
Max.
ALARM
Power
3.4 Controller Wiring and Output Hookups
CableclearancedimensionsforthearraysareshowninFigure3-3.
Controllerconnectionsaremadeviathewiringterminalsalongthefrontsurface
ofeachmodule.Emitterandreceiverhookupsandcontrolleroutputsareshownin
Figures3-5through3-11.
3.4.1 Model MAC-1 Controller Hookup
Output 1:Controllerterminals#9and#10(OUT1)arereedrelaycontactsrated
at125Vac/dcmax.,10VAmax.resistive(i.e.,non-inductive)load.Itmaybe
programmedaseithernormallyopenornormallyclosed.
Alarm:Controllerterminal#15(Alarm)isanopen-collectorNPNtransistorswitch
ratedat30Vdcmax.,150mAmax.Itisprotectedagainstoverloadandshortcircuits.
3.4.2 Model MACP-1 Controller Hookup
Output 1:Controllerterminal#9(OUT1)isanopen-collectorPNPtransistorswitch
ratedat30Vdcmax.,150mAmax.Itisprotectedagainstoverloadandshortcircuits.
Alarm:Controllerterminal#15(ALARM)isanopen-collectorPNPtransistorswitch
ratedat30Vdcmax.,150mAmax.Itisprotectedagainstoverloadandshortcircuits.
Bothoutputsarecurrentsourcing.
Figure 3-6. Model MACP-1 hookup
1
+
–+ –
10-30V dc
Gate
16-30V dc
1.2 A Max.
234
5678
9
101112131415
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
V- V+
RS485 Com
30V
150 mA
Max.
ALARM
30V
150 mA
Max.
Out
Power
V+ V+

16 P/N 43298 rev. E
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
Installation and Mechanical Alignment
1
+
–+ –
10-30V dc
Gate
16-30V dc
1.2 A Max.
234
5
678
9
10131415
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
V- V+
RS485 Out 1
30V
150 mA
Max.
30V
150 mA
Max.
ALARM
Power
12 11
Com
1
+
–
10-30V dc
Gate
16-30V dc
1.2 A Max.
234
5678
9
10131415
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
V- V+
30V
150 mA
Max.
ALARM
0-10V
10 mA
V out 2
Power
12 11
Com Com
0-10V
10 mA
Max.
V out 1
Figure 3-7. Model MACN-1 hookup
Figure 3-8. Model MACV-1 hookup
3.4.3 Model MACN-1 Controller Hookup
Output 1:Controllerterminal#9(OUT1)isanopen-collectorNPNtransistorswitch
ratedat30Vdcmax.,150mAmax.Itisprotectedagainstoverloadandshortcircuits.
Alarm:Controllerterminal#15(ALARM)isanopen-collectorNPNtransistorswitch
ratedat30Vdcmax.,150mAmax.Itisprotectedagainstoverloadandshortcircuits.
Bothoutputsarecurrentsinking.
3.4.4 Model MACV-1 Controller Hookup
Voltage outputs 1 and 2:Controllerterminals#9(Vout1)and#13(Vout2)are
analogvoltageoutputs.TheloadforanalogvoltageOutput#1shouldbetiedacross
terminals#9and#10.TheloadforanalogvoltageOutput#2shouldbetiedacross
terminals13and14.Bothswitchesareratedat10Vdcmax.,10mAmax.Both
outputsarevoltagesourcing.
Alarm:Controllerterminal#15(ALARM)isanopen-collectorNPNtransistorratedat
30Vdcmax.,150mAmax.,currentsinking.

P/N 43298 rev. E 17
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
Installation and Alignment
3.4.5 Model MACI-1 Controller Hookup
Current outputs 1 and 2:Controllerterminal#9(Iout1)and#13(Iout2)areanalog
currentoutputs.TheloadforanalogcurrentOutput#1shouldbeconnectedbetween
anexternal16to30Vdcpowersupplyandterminal#9.Theloadforanalogcurrent
Output#2shouldbeconnectedbetweenanexternal16to30Vdcpowersupply
andterminal13.Theloadexternalpowersupplyreturnshouldbecommonwiththe
controllerpowersupplyreturn.Bothoutputsarecurrentsinking.
Alarm:Controllerterminal#15(ALARM)isanopen-collectorNPNtransistorratedat
30Vdcmax.,150mAmax.Itisprotectedagainstoverloadandshortcircuits.
1
+
–
10-30V dc
Gate
16-30V dc
1.2 A Max.
234
5678
9
10131415
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
V- V+
30V
150 mA
Max.
ALARM
Power
12 11
Com Com
4-20 mA
I out 2
4-20 mA
I out 1
3.4.6 Model MAC16P-1 Controller Hookup
Terminals#15through#30areopen-collectorPNPtransistoroutputsratedat30V
dcmax.,150mAmax.Theyareprotectedagainstoverloadandshortcircuits.The
isolatedgateinputisatpins11and12.
Controllerterminal#15(output#16)maybeusedasanoutputorasanalarm.
Wheneverthisoutputisactive,theredAlarmLEDisON.
Alloutputsarecurrentsourcing.
Figure 3-9. Model MACI-1 hookup
1
+
–
10-30V dc
Gate
16-30V dc
1.2 A Max.
234
5
678
9
101314
15 30
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
V- V+
Power
12 11
NC NC NC NC
through
16 Solid-state Ouputs V+
150 mA Max each
Figure 3-10. Model MAC16P-1 hookup

18 P/N 43298 rev. E
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
Figure 3-12. DB9 serial connector
3.5 System Power
Connecta16to30Vdcsourcetocontrollerterminals#1(V+)and#2(V–).Connect
agoodearthgroundtoterminal#3.Agoodearthgroundisimportantforproviding
electricalandRFnoiseimmunitytotheMINI-ARRAYSystem.Thedcpowersource
mustsupply1.25amps(worstcase)whenusingthelongest(6')sensors.See
Specifications(Section2)formoreinformation.
3.6 Gate
Connectaswitched10to30Vdcsourceasagatinginput(ifrequired)between
controllerterminal#11(+)and#12(-).Voltageistypicallyswitchedbytheopen-
collectoroutputtransistorofadcsensingdevice.
3.7 Serial Communication
RS-485 (Models MAC-1, MACP-1, and MACN-1 only)
ConnectRS-485lines(ifused)toterminals#13(+)and#14(-).
RS-232
PrepareanRS-232cableusingaDB-9maleconnectorwiththeconnectionsshownin
Figure3-12.
NOTE: DO NOT use a “null modem” RS-232 cable.
RS-232
523 2- TX
3- RX
5- COM
DB-9 Pin # Function
Ground (GND)
Receive (RX)
Transmit (TX)
5
3
2
Installation and Alignment
3.4.7 Model MAC16N-1 Controller Hookup
Terminals#15through#30areopen-collectorNPNtransistoroutputsratedat
30Vdcmax.,150mAmax.Theyareprotectedagainstoverloadandshortcircuits.
Alloutputsarecurrentsinking.
Controllerterminal#15(output#16)maybeusedasanoutputorasanalarm.
Wheneverthisoutputisactive,theredAlarmLEDisON.
1
+
–
10-30V dc
Gate
16-30V dc
1.2 A Max.
234
5
678
9
101314
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
V- V+
Power
12 11
NC NC NC NC
15 30
through
16 Solid-state Ouputs
150 mA Max each
Figure 3-11. Model MAC16N-1 hookup

P/N 43298 rev. E 19
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
Software Installation
4. Software Installation
The Parameter Setup Software CD includes an installation program that quickly and easily loads the MINI-ARRAY configuration program into the computer.
The 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) per the following:
Models MAC-1, MACI-1, MACN-1, MACP-1, MACV-1: CD P/N 75877
Models MAC16N-1, MAC16P-1: CD P/N 75878
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

20 P/N 43298 rev. E
Banner Engineering Corp. •Minneapolis,MNU.S.A.
www.bannerengineering.com•Tel:763.544.3164
MINI-ARRAY®
InstructionManual
ConfigurationoftheMINI-ARRAYcontrollerisaccomplishedwithaWindows®menu-
styleprocedure,usingtheBanner-suppliedsoftwareandaPC-compatiblecomputer
runningWindows®XP, Vista, or 7.Aserialdataconnectionismade
betweenthecomputerandtheDB9connectoronthecontroller(seeFigure3-12).
ParameterSetupFiles(PSF)areprogrammedconfigurationsthatcanbestoredinthe
controlmodule’snon-volatilememory.TheBannersoftwarecanstorevariousPSFsin
computerfilesforinstantcall-upofaparticularconfiguration.
TheBannersoftwarealsoprovidestwoadditionalfeatures:AnAlignmentscreenanda
Diagnosticsscreen
5.1 Communications Setup
TheMINI-ARRAYsoftwarepermitsserialcommunicationviaRS-232betweentheMAC
controllerandthePC.TheminimumconnectionstotheDB-9connectoronthe
MINI-ARRAYControllersareasfollows:
Figure 5-1. MINI-ARRAY software Option
menu
Figure 5-2. MINI-ARRAY software Main
menu
NOTE: DO NOT use a “null modem” RS-232 cable.
ConfiguretheCOMportofthePCbyfirstselectingtheOptionsmenu(seeFigure
5-1).Theprogramsupportsserialcommunicationviathe.COM1-COM20.port.
ofthecomputer.SelectOptions,thenselectSerial Port(orEnter).Selecteither
COM1orCOM2.CheckSave Settings on Exit (ifitisnotalreadychecked)tostore
theCOMportselection.
5.2 Alignment Analysis
AlignmentstatusiscontinuouslydisplayedbythegreenLEDindicatorontheReceiver
andthecontroller.Whenallunblankedbeamsareclear,andexcessgainofallbeams
ismorethan3x,thegreenalignmentindicatorswillbeON.Whentheexcessgain
ofoneormorebeamsdropstobetween3xand1x,thegreenALIGNLEDonthe
controllerwillremainON,buttheyellowLEDonthereceiverwillcomeONtoindicate
awarningofmarginalalignment.SeeSection6formoreinformationaboutsensor
alignment.
OnefeatureoftheMINI-ARRAYsoftwareisaprogramthatdisplaysthestatusof
eachbeaminthearray.Thisroutinecanbeveryhelpfulforfinalalignmentorwhen
analyzinghowtheMINI-ARRAYisviewingobjectsinthesensingarray.Tolaunchthis
program,selectAlignment...undertheMINI-ARRAYmenu(seeFigure5-2),or
presstheF3key.
Controller Configuration
5. Controller Configuration
Pin Number of DB-9 Function
2Transmit(TX)
3Receive(RX)
5 Ground(GND)