Banner A-GAGE EZ-ARRAY User manual

A-GAGE®EZ-ARRAY™with IO-Link v1.1
Instruction Manual
Original Instructions
222662 Rev. B
4 May 2021
©Banner Engineering Corp. All rights reserved
222662

Contents
1 Features ..........................................................................................................................................................................3
2 Overview ........................................................................................................................................................................4
2.1 System Components .......................................................................................................................................................................5
2.2 Models ..............................................................................................................................................................................................5
2.3 Status Indicators ............................................................................................................................................................................. 5
2.3.1 Zone Indicators (Beams Blocked Segment) ............................................................................................................................ 6
2.3.2 Three-Digit Display .................................................................................................................................................................. 6
2.3.3 Blanking Indicator .................................................................................................................................................................... 6
2.3.4 Electronic Configuration Indicator ............................................................................................................................................6
3 Configuration via DIP Switch or IO-Link v1.1 Interface ..............................................................................................8
3.1 Receiver Gray (Remote Teach) Wire ..............................................................................................................................................8
3.2 Gain Configuration ........................................................................................................................................................................... 9
3.3 Blanking ........................................................................................................................................................................................ 10
3.4 Measurement Mode Selection ...................................................................................................................................................... 10
3.5 Outputs ...........................................................................................................................................................................................13
3.5.1 Analog Output Configuration ................................................................................................................................................. 13
3.5.2 Discrete Output Configuration ............................................................................................................................................... 13
3.6 Scanning Method .......................................................................................................................................................................... 13
3.6.1 Straight Scan ......................................................................................................................................................................... 14
3.6.2 Single-Edge Scan ..................................................................................................................................................................14
3.6.3 Double-Edge Scan ................................................................................................................................................................ 14
3.6.4 Maximum Scan Times in SIO Mode ....................................................................................................................................... 15
4 Installation Instructions ............................................................................................................................................. 16
4.1 Mounting the Emitter and Receiver ...............................................................................................................................................16
4.2 Mechanical Alignment ...................................................................................................................................................................16
4.3 Wiring Diagrams .............................................................................................................................................................................18
4.4 Optical Alignment ..........................................................................................................................................................................19
5 Receiver User Interface ..............................................................................................................................................21
5.1 Configuration DIP Switches .......................................................................................................................................................... 21
5.1.1 Scanning Modes (S1 and S2) ................................................................................................................................................22
5.1.2 Measurement Modes (S3 and S4) .........................................................................................................................................22
5.1.3 Analog Slope (S5) .................................................................................................................................................................. 22
5.1.4 Complementary/Alarm (S6) ................................................................................................................................................... 22
5.2 Alignment/Blanking Button (Electronic Alignment) ........................................................................................................................22
5.2.1 Electronic Alignment and Blanking - Receiver Interface ........................................................................................................23
5.2.2 Flashing "000" on the 3-Digit Display .................................................................................................................................... 23
5.3 Gain (Sensitivity Adjust) Button .....................................................................................................................................................23
5.4 Inverting the 3-Digit Display ........................................................................................................................................................... 23
6 Additional Information ............................................................................................................................................... 24
6.1 IO-Link Overview ...........................................................................................................................................................................24
6.2 IO-Link v1.1 Profile and Models .....................................................................................................................................................24
6.3 Hardware Interface ........................................................................................................................................................................24
6.3.1 Electrical Interface ................................................................................................................................................................. 24
6.3.2 IO-Link Master ....................................................................................................................................................................... 25
6.4 IODD (IO-Link Device Description) and Parameters ......................................................................................................................25
7 Troubleshooting ......................................................................................................................................................... 26
7.1 Error Codes ....................................................................................................................................................................................26
7.2 "Dirty" Channel Indicator ...............................................................................................................................................................26
8 Specifications .............................................................................................................................................................. 27
8.1 Emitter and Receiver Dimensions ..................................................................................................................................................28
8.2 Standard Bracket Dimensions .......................................................................................................................................................29
9 Accessories ..................................................................................................................................................................30
9.1 Cordsets and Connections ............................................................................................................................................................30
9.2 Alignment Aids ............................................................................................................................................................................... 31
9.3 Accessory Mounting Brackets and Stands ....................................................................................................................................32
10 Product Support and Maintenance ......................................................................................................................... 33
10.1 Replacement Parts ......................................................................................................................................................................33
10.2 Contact Us ................................................................................................................................................................................... 33
10.3 Banner Engineering Corp. Limited Warranty .............................................................................................................................. 33
A-GAGE® EZ-ARRAY™ with IO-Link v1.1

1 Features
• A cost-effective, two-piece measuring light curtain designed for quick and simple
installations with the sophistication to handle the toughest sensing applications
• Excels at high-speed, precise process monitoring and inspection, profiling, and
web-guiding applications
• A comprehensive combination of scanning options:
◦ 16 measurement (scan analysis) modes
◦ Three scanning methods
◦ Selectable beam blanking
◦ Selectable continuous or gated scan initiation
◦ Selectable threshold setting for semi-transparent applications
◦ Two analog outputs, two discrete outputs
◦ Communication via IO-Link v1.1 interface
• Outstanding 4 meter range with 5 mm beam spacing
• Available in 12 lengths from 150 mm to 2400 mm
• Excellent 5 mm minimum object detection or 2.5 mm edge resolution, depending
on scanning method
• Receiver user interface for quick, intuitive setup of many common applications:
◦ Six-position DIP switch for setting scan mode, measurement mode, analog
slope, discrete output 2 option (complementary measurement or alarm
operation)
◦ Two push buttons for gain method selection and alignment/ blanking
◦ Seven Zone LEDs for instant alignment and beam blockage information
◦ Three-digit display for sensing information and diagnostics
• Advanced configuration via IO-Link v1.1 communication interface
• Remote teach wire option for alignment, gain settings, inverted display, and DIP
switch disable
WARNING:
•Do not use this device for personnel protection
• Using this device for personnel protection could result in serious injury or death.
• This device does not include the self-checking redundant circuitry necessary to allow its use in
personnel safety applications. A device failure or malfunction can cause either an energized (on)
or de-energized (off) output condition.
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2 Overview
The A-GAGE® EZ-ARRAY™ measuring light screen is ideal for such applications as on-the-fly product sizing and profiling,
edge-guiding and center-guiding, loop tensioning control, hole detection, parts counting, and similar uses.
Emitters and receivers are available with arrays from 150 to 2400 mm (5.9 in to 94.5 in) long. The emitter has a column of
infrared light emitting diodes (LEDs) spaced 5 mm apart; their light is collimated and directed toward the receiver, positioned
opposite the emitter, which has photodiodes on the same 5 mm pitch. The light from each emitter LED is detected by the
corresponding receiver photodiode.
This sophisticated light curtain is capable of detecting opaque cylindrical objects as small as 5mm in diameter or measuring
part edges within 2.5 mm, depending on the scanning method selected ( Scanning Method on p. 13). The sensing range is
400 mm to 4 m (16 in to 13 ft) on standard models and 30 mm to 1500 mm (1.18 in to 59 in) on the short-range, low-contrast
models. 1
Short range, low contrast models are available for applications requiring a shorter distance between emitter and receiver or
where detection and profiling of non-opaque targets is needed. Detection of glass or other clear objects is possible with this
system.
The EZ-ARRAY’s two-piece design makes it economical and easy to use. Controller functionality is built into the receiver
housing. It can be configured for many straightforward applications using the six-position DIP switch on the front of the
receiver (the receiver user interface).The IO-Link communication interface provides the capability for more advanced control
and monitoring. See Additional Information on p. 24.
The emitter and receiver housings can be side-mounted or end-cap-mounted using the included end-cap brackets; longer
models also include a center bracket. (See Mounting the Emitter and Receiver on p. 16.)
Beam synchronization is achieved via the 8-conductor sensor cables. Individual LEDs and a 3-digit diagnostic display on the
receiver provide ongoing visual sensing status and diagnostic information. Comprehensive data is available to a process
controller via a combination of four outputs: two analog and two discrete (discrete output 1 is an IO-Link output). The IO-Link
output provides a discrete output (SIO mode) or a communication interface (IO-Link mode).
Figure 1. Application Figure 2. Emitter and Receiver
Beam #1
(Closest to
Display)
Power ON
LED
Emitter Receiver
3-Digit Diagnostic
Display
Screw-on Security Plate
limits access to DIP switch
and push buttons
Zone Indicators
Gain (Sensitivity Adjust)
Push Button
6-Position
Configuration
DIP Switch
Alignment/Blanking
Push Button
Under Hinged Access Panel:
Status, Communication Active, and
Communication Error LEDs
Built-in features in the EZ-ARRAY contribute to its ease of use. Many features are available using either the user-friendly
receiver interface or the more advanced IO-Link v1.1 interface.
Diagnostic programming and easy-to-see indicators on the receiver simplify physical alignment and troubleshooting; more
advanced diagnostics are available via the IO-Link v1.1 interface.
The alignment/blanking button ( Alignment/Blanking Button (Electronic Alignment) on p. 22) automatically equalizes the
excess gain of each beam for reliable object detection throughout the array. This routine need not be performed again unless
the sensing application changes, or if the emitter and/or receiver is moved.
Configurable beam blanking accommodates machine components and fixtures that must remain in or move through the light
screen. Blanking may be set using the receiver interface, the teach wire, or the IO-Link v1.1 interface.
The EZ-ARRAY light screen provides a wide selection of sensing and output options, including measurement (“scan
analysis”) modes and scanning methods that can determine a target object’s location, overall size, total height, or total width,
or the number of objects. Scanning may be continuous or controlled by a gate sensor.
1Contact the factory for short-range, low-contrast models.
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2.1 System Components
A typical A-GAGE EZ-ARRAY has four components: an emitter
and a receiver, each with an integral quick-disconnect (QD) fitting,
plus an 8-pin QD cordset for the emitter and for the receiver.
For applications that use the IO-Link interface, an additional cable
splitter is used to convert the receiver 8-pin connector to a
compatible M12 connector.
Figure 3. Components
2.2 Models
Emitter Receiver with IO-Link
v1.1
Receiver Discrete Output
2Receiver Analog
Output Array Length Y 3Total Beams
EA5E150Q EA5R150XK2Q PNP Voltage (0-10 V) 150 mm (5.9 in) 30
EA5E300Q EA5R300XK2Q PNP Voltage (0-10 V) 300 mm (11.8 in) 60
EA5E450Q EA5R450XK2Q PNP Voltage (0-10 V) 450 mm (17.7 in) 90
EA5E600Q EA5R600XK2Q PNP Voltage (0-10 V) 600 mm (23.6 in) 120
EA5E750Q EA5R750XK2Q PNP Voltage (0-10 V) 750 mm (29.5 in) 150
EA5E900Q EA5R900XK2Q PNP Voltage (0-10 V) 900 mm (35.4 in) 180
EA5E1050Q EA5R1050XK2Q PNP Voltage (0-10 V) 1050 mm (41.3 in) 210
EA5E1200Q EA5R1200XK2Q PNP Voltage (0-10 V) 1200 mm (47.2 in) 240
EA5E1500Q EA5R1500XK2Q PNP Voltage (0-10 V) 1500 mm (59.1 in) 300
EA5E1800Q EA5R1800XK2Q PNP Voltage (0-10 V) 1800 mm (70.9 in) 360
EA5E2100Q EA5R2100XK2Q PNP Voltage (0-10 V) 2100 mm (82.7 in) 420
EA5E2400Q EA5R2400XK2Q PNP Voltage (0-10 V) 2400 mm (94.5 in) 480
2.3 Status Indicators
Both the emitter and receiver provide ongoing visual indication of operating and configuration status.
The emitter has a red LED that signals proper operation (ON when power is applied).
2Discrete Output 1 is push-pull (IO-Link)
3Models with array lengths 1050mm and longer ship with a center bracket as well as two end-cap brackets.
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Table 1: Emitter status indicators
LED Color Description
Status LED
Red ON Status OK
Red Flashing at 1 Hz Error
The receiver has a bright Status LED that indicates overall sensing status (OK, marginal alignment, and hardware error). Two
other LEDs indicate whether communication is active or if there is an error. Seven Zone indicators each communicate the
blocked/aligned status of one-seventh of the total array. A 3-digit diagnostic display provides further diagnostic information:
number of beams blocked, whether blanking is configured, and error codes. (See Error Codes on p. 26 for a listing of error
codes.)
Table 2: Receiver and IO-Link status indicators
LED Indicator Color Description
7-Zone Indicators
Red Blocked channels within the zone
Green All channels are clear within the zone
Status
Red Marginal alignment or hardware error; check the 3-digit display
Green System is okay
COMM
Amber On IO-Link mode
Amber Off SIO mode
Error Red IO-Link error; check the cabling or master controller
2.3.1 Zone Indicators (Beams Blocked Segment)
Seven LEDs represent emitter/receiver alignment status. They provide a visual aid for sensor alignment and monitoring
objects within the sensor’s field of view. The sensor array is partitioned into seven equal segments, each of which is
represented by one of the seven LEDs. The LED closest to DIP switch S6 (see Configuration via DIP Switch or IO-Link v1.1
Interface on p. 8) represents the group of optical channels closest to the receiver display (the “bottom” group). The LED
closest to DIP switch 1 represents the far segment of channels.
These LEDs illuminate either green or red. When an LED is green, no unblanked beams are obstructed in that segment.
When the LED is red, one or more beams in that segment is obstructed.
2.3.2 Three-Digit Display
The 3-digit display has slightly different functions during normal operation, alignment, and gain adjust modes. In normal
operation the display indicates the current numerical value of measurement mode 1. The display also identifies the following
activated sensor functions: blanking and locked-out user interface/electronic configuration, as shown in Electronic
Configuration Indicator on p. 6.
For directions for inverting the display, see Receiver Gray (Remote Teach) Wire on p. 8 or see HW Interface Flags in
Configuration via DIP Switch or IO-Link v1.1 Interface on p. 8.
During blanking mode, the display reads “n”, followed by the number of blocked beams in the array. During alignment mode,
it reads “A”, followed by the number of blocked, unblanked beams; a period follows the A (“A.”) if blanking is configured.
During gain adjust mode, the display reads “ L ” followed by “1” or “2” to indicate the gain level. (A “1” represents high excess
gain, and a “2” represents low contrast.)
If a sensing error occurs, the display reads “c” followed by a number that corresponds to the recommended corrective action.
Refer to Error Codes on p. 26 for more information.
2.3.3 Blanking Indicator
The Blanking indicator will be visible (ON) when the blanking feature is enabled. It appears as a period following the first digit
of the display.
2.3.4 Electronic Configuration Indicator
The Electronic Configuration indicator is on when the sensor configuration is defined by the IO-Link v1.1 interface and not the
DIP switch. When electronic configuration is enabled, the DIP switch is ignored.
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Figure 4. Electronic configuration indicator
Period ON
indicates
Blanking
Configured
‘A’ in this
position indicates
Alignment mode
Period ON indicates
Electronic Configuration
Enabled
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3 Configuration via DIP Switch or IO-Link v1.1 Interface
Commonly used configuration options can be set up easily via a six-position DIP switch located behind a hinged clear access
panel on the front of the receiver.
Access to the DIP switch can be prevented by using the screw-on security plate to hold the clear access panel closed or by
disabling them via the IO-Link v1.1 interface.
3.1 Receiver Gray (Remote Teach) Wire
The receiver gray (remote teach) wire is used to electronically emulate the receiver push button functions (see
Troubleshooting and Error Codes) via a process controller, to disable the DIP switches for security, or to provide a gate input
to initiate sensor scanning. Connect a normally open switch between the receiver's gray wire and dc common, or connect the
gray wire to a digital input (PLC) and pulse the wire as indicated in Status Indicators on p. 5.
The Remote Teach wire is disabled by default. It can be enabled via the IO-Link interface.
Note: A low level is 0 to 2 volts and a high level is 10 to 30 volts or circuit open. Input impedance is 22k.
Remote TEACH/Gate determines the functionality of the receiver gray wire.
•Disabled—The remote wire has no function (regardless of whether it is low or high). When the gray wire is disabled,
the receiver is in continuous scan mode; it begins a new scan immediately after updating the outputs from the
previous scan. (Continuous scan is used in most analog output applications and whenever continuous updating of the
outputs is acceptable.) The gray wire is always enabled when in DIP switch mode.
•Remote Teach—The gray wire provides the full Remote Teach functionality.
•Alignment/Sensitivity—This mode is an abbreviated version of Remote Teach. It can perform the alignment and
sensitivity adjustment functions, but not the display inversion or DIP switch enable/disable functions.
Gate Mode—Options enable the gray wire to be wed as a gate input pulse, typically from a dc device such as an NPN-output
photoelectric sensor or a PLC discrete output.
•Gate - Active High—The receiver scans whenever the gate is pulled high.
•Gate - Active Low—The receiver scans whenever the gate is pulled low.
•Gate - Rising Edge—The receiver scans once for each low-to-high gate transition. (Multiple transitions cannot be
faster than the sensor's response for them to be reliably detected.)
•Gate - Falling Edge—The receiver scans once for each high-to-low gate transition. (Multiple transitions cannot be
faster than the sensor's response for them to be reliably detected.)
Table 3: Alignment/blanking configuration with the remote wire
Process Remote Wire Procedure 0.05 ≤ sec. T ≤ 0.8
sec. Result
Alignment /
Blanking
Access Alignment Mode
1X
A appears on 3-digit display
Access Blanking Mode
From Alignment Mode:
2X
n appears on 3-digit display, along with number of blocked
beams
Exit Blanking Mode
1X
A. appears on 3-digit display (sensor returns to alignment
mode with blanking enabled)
Exit Alignment Mode
1X
Sensor returns to run mode
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Table 4: Gain, receiver interface, and display configuration with the remote wire
Process Remote Wire Procedure 0.05 ≤ sec. T ≤ 0.8
sec. Result
Gain Method
Access Gain Mode
From Run Mode:
2X
L appears on 3-digit display, along with number 1 or 2, to
designate gain level
Toggle Between Gain
Settings
1X
Number changes from number 1 to 2, back to 1, etc.
Save Gain Level and
Exit
When correct level is displayed:
2X
Gain level is configured:
1 = High-excess-gain setting
2 = Low-contrast setting
Sensor returns to run mode
Invert Display Invert Display
3X
Display inverts from previous state; sensor continues in
run mode
Receiver
Interface
Enable/Disable
Receiver Interface
Enable/Disable
4X
The factory default is Receiver Interface enabled.
Four-pulsing the remote line saves the current settings
and disables the interface (the sensor continues to
operate using the saved settings; changes made to the
DIP switch will have no effect).
Repeating the process enables the Receiver Interface so
that settings can be changed.
3.2 Gain Configuration
The EZ-ARRAY provides two gain options for straight scan applications: high excess gain and low contrast. The gain method
can be selected using the receiver push button, the receiver remote teach wire, or the IO-Link v1.1 interface.
High (maximized) excess gain is suited for detecting opaque objects and for reliable sensing in dirtier environments where
objects to be detected are 10 mm or larger. The high excess gain method is always used in single- and double-edge scan.
The high excess gain option has a minimum blocked threshold level, which provides reliable sensing at higher excess gain
levels.
The low-contrast setting is used for sensing semi-transparent materials and for detecting objects as small as 5 mm
(straight scan only). In low-contrast operation, only a portion of a beam must be blocked for detection to occur. In low-
contrast operation, the sensor sets an individual threshold for each optical channel during the alignment process; this
process equalizes the signal strength to allow semi-transparent object detection.
When using the IO-Link v1.1 interface, low-contrast sensing provides a fine-tune sensitivity setting of 15% to 50%. When
using the receiver interface, low-contrast sensitivity is always 30%.
On short range, low contrast models, sensitivity can be set between 3% to 20% when using the IO-Link v1.1 interface. When
using the receiver interface, low contrast sensitivity is always 7%.
Table 5: Gain configuration settings
Gain Setting Scan Method EZ-ARRAY MODS 4EZ-ARRAY Resolution
Low Contrast Straight Scan 5 mm 5 mm
Single-edge Scan - -
Double-edge Scan - -
High Excess Gain Straight Scan 10 mm 5 mm
Single-edge Scan 10 mm 2.5 mm
Double-edge Scan Depends on step size 2.5 mm / edge 5 mm total (both
edges)
4MODS: Minimum Object Detection Size
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3.3 Blanking
If a machine fixture or other equipment blocks one or more sensing beams, the affected beam channels may be blanked. The
blanking option causes the receiver to ignore the status of blanked beams for measurement mode calculations.
For example, if a machine fixture blocks one or more beams during sensing, the output data will be incorrect; if the beams
blocked by the fixture are blanked, the output data will be correct. Blanking may be configured using the receiver's Alignment
push button, the receiver remote wire, or the IO-Link v1.1 interface.
3.4 Measurement Mode Selection
The outputs may be configured for any of the measurement (scan analysis) modes, which refer to specific beam locations,
quantities of beams, or edge transitions. Note that not all measurement mode options are available when the receiver
interface is used for configuration.
When using the IO-Link v1.1 interface for configuration, discrete output 2 can have NPN or PNP polarity (regardless of
model), be normally open or normally closed, and be assigned to any of the measurement modes. Discrete output 1 has the
same configuration options as discrete output 2, except for NPN or PNP polarity. Discrete output 1 is the IO-Link output and
is a dedicated push-pull output. When using the receiver interface, limited output configuration combinations may be selected
(see Configuration via DIP Switch or IO-Link v1.1 Interface on p. 8).
Note: Array beams are numbered in sequence (beam 1 located nearest the sensor display). The "first
beam" referenced in the following descriptions is the beam nearest the sensor display.
"Beam Location" Modes
First Beam Blocked (FBB)
The location of the first blocked beam.
First Beam Made (FBM)
The location of the first made (unblocked) beam.
Last Beam Blocked (LBB)
The location of the last blocked beam.
Last Beam Made (LBM)
The location of the last made beam.
Middle Beam Blocked (MBB)
The location of the beam midway between the first and last blocked beams.
"Beam Total" Modes
Total Beams Blocked (TBB)
The total number of blocked beams.
Total Beams Made (TBM)
The number of beams made.
Contiguous Beams Blocked (CBB)
The largest number of consecutively blocked beams.
Contiguous Beams Made (CBM)
The largest number of consecutively made beams.
Outside Dimension (OD)
The inclusive distance (measured in beams) from the first blocked beam to the last blocked beam.
Inside Dimension (ID)
The number of made beams, between the first and last blocked beams.
Transitions (TRN)
The number of changes from blocked to clear status and from clear to blocked status. (If beams 6–34 are blocked,
then there is a clear-to-blocked transition from beam 5 to bream 6, and a blocked-to-clear transition from beam 34 to
beam 35.) Transition mode can be used to count objects within the array.
Contiguous First Beam Blocked (CFBB)
The location of the first blocked beam in the largest group of adjacent blocked beams.
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Contiguous Last Beam Blocked (CLBB)
The location of the last blocked beam in the largest group of adjacent blocked beams.
Carpet Nap and Carpet Edge
These measurement modes are used to measure the location of carpet backing and tuft and are selectable only via
the IO-Link v1.1 interface and only when the Scan Type Carpet Nap is selected. The modes can be measured from
either end of the sensor, but at least 10 beams (2 in) must be blocked from one edge.
Figure 5. Measurement mode - LBM-FBM
Last Beam Made (LBM)
First Beam Made (FBM)
Receiver
Emitter
10
20
30
40
50
60
In Last Beam Made mode, the last beam is #50 of 60. In First Beam Made mode, the first beam is #40 of 60.
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Figure 6. Measurement mode - LBB-FBB
Last Beam Blocked (LBB)
First Beam Blocked (FBB)
Receiver
Emitter
10
20
30
40
50
60
In Last Beam Blocked mode, the last beam is #55 of 60. In First Beam Blocked mode, the first beam is #20 of 60.
Figure 7. Measurement mode - TBM-TBB
Total Beams Made (TBM)
Total Beams Blocked (TBB)
Receiver
Emitter
10
20
30
40
50
60
In Total Beams Made mode, 38 of 60 possible beams are made. In Total Beams Blocked mode, 22 of 60 possible beams are
blocked.
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3.5 Outputs
All models have two analog outputs and two discrete outputs (discrete output 1 is an IO-Link output).
The analog outputs are 0–10 V. They may be configured (via DIP switch or IO-Link interface) for either a positive or negative
slope.
Discrete output 1 is always used for measurement; discrete output 2 may be used either for alarm or measurement operation
(selectable via DIP switch or IO-Link interface). When the receiver interface is used, discrete output 1 and analog output 1
follow the same measurement mode. When the IO-Link interface is used for configuration, discrete output 2 has full
configurability, including measurement mode, NPN or PNP polarity, and normally open or normally closed operation. Discrete
output 1 has the same configurability as discrete output 2, except for NPN or PNP polarity. Discrete output 1 is a dedicated
push-pull output.
3.5.1 Analog Output Configuration
Analog output configuration assigns analog outputs 1 and 2 to one of the measurement modes described in Measurement
Mode Selection. When the selected measurement mode involves first or last beam blocked or made (unblocked), the
assigned output will vary in proportion to the beam number identified during a scan. When the measurement mode involves
total beams blocked or made, that assigned output will vary in proportion to the total beams counted during a scan.
Analog outputs may have a filter setting (to smooth the output) and Zero Value (to specify the output value when the
measurement mode value is zero) set in the IO-Link v1.1 interface. For more information, refer to the IO-Link Data Reference
Guide (p/n 220588).
3.5.2 Discrete Output Configuration
Discrete Output 1; Receiver Interface
When the receiver interface is used for configuration, the measurement mode assigned to discrete output 1 is the
same as that assigned to analog output 1. When the analog output detects a target present, discrete output 1
conducts (normally open).
Discrete Output 2; Receiver Interface
Discrete output 2 (only) has two options: alarm and complementary (measurement) operation.
Alarm—Output 2 energizes when the receiver detects a sensor error (such as a disconnected cable) or
whenever the excess gain of one or more beams becomes marginal.
Complementary (Measurement)—Discrete output 2 operation is complementary to discrete output 1 (when
output 1 is ON, output 2 is OFF, and vice versa).
Discrete Output 1 and 2 Configuration; IO-Link v1.1 Interface
When the IO-Link v1.1 interface is used for configuration, the discrete outputs have more options: either discrete
output can be assigned to any of the measurement modes, high and low set points can be added, the outputs can
be inverted, and hysteresis values can be set, as well as a scan number to smooth output performance. Discrete
output 2 can be assigned to alarm mode via the IO-Link v1.1 interface also.
Refer to the IO-Link Data Reference Guide (p/n 220588)
3.6 Scanning Method
One of three scanning methods may be configured:
• Straight Scan
• Single-edge Scan
• Double-edge Scan (1, 2, 4, 8, 16, or 32 steps)
Sensor response time is a function of sensor length and scanning method. Maximum scan times are shown in Maximum
Scan Times in SIO Mode on p. 15.
Scanning
Method
Straight Scan Single-Edge
Scan
Double-Edge Scan (per Edge)
Low-
Contrast
High-Excess-
Gain
Step Size (Number of Beams)
1 2 4 8 16 32
Minimum Object
Detection Size*
5 mm
(0.2") 10 mm (0.4") 10 mm (0.4") 10 mm (0.4")
20 mm
(0.8")
30 mm
(1.2") 50 mm (2") 90 mm (3.6")
170 mm
(6.8")
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Scanning
Method
Straight Scan Single-Edge
Scan
Double-Edge Scan (per Edge)
Low-
Contrast
High-Excess-
Gain
Step Size (Number of Beams)
1 2 4 8 16 32
Edge Resolution 5 mm
(0.2") 5 mm (0.2") 2.5 mm (0.1") 2.5 mm (0.1")
2.5 mm
(0.1")
2.5 mm
(0.1")
2.5 mm
(0.1")
2.5 mm
(0.1")
2.5 mm
(0.1")
*MODS determined using a rod target object
3.6.1 Straight Scan
Straight Scan is the default mode, in which all beams are scanned in sequence, from the display end to the far end of the
array. This scanning method provides the smallest object detection size.
Straight scan is used when low-contrast sensitivity is selected or when single-edge and double-edge scan cannot be used.
The edge resolution is 5 mm (0.2 in). When low-contrast sensing is selected (used when measuring semi-transparent
objects), the minimum object detection size is 5 mm (0.2 in) diameter. When high-excess-gain sensing is selected, the
minimum object detection size is 10 mm (0.4 in).
3.6.2 Single-Edge Scan
Single-Edge Scan is used to measure the height of a single object. This scanning method is commonly used for box height
measurement. For single-edge scan, the receiver always activates the first beam channel (or "bottom" beam, nearest the
display). When the first beam is blocked, the sensor performs a binary search to hunt for the last beam blocked, as follows:
1. The receiver scans only the first beam until it is blocked.
2. When the first beam is blocked, the sensor looks to see whether the middle beam is blocked or made (unblocked).
3. If the middle beam is made (unblocked), the sensor checks the bottom quarter beam; if the middle beam is blocked,
the sensor checks the top quarter beam.
4. The routine continues to divide the number of beams in half until the edge is found.
Single-edge scan can be used only for single, solid objects that block the first beam (closest to the display). Because the
receiver checks only the first beam until it is blocked, single-edge scan will not function when the item to be measured does
not block the first beam. Single-edge scan is also ineffective if the object does not present a continuous blocked pattern.
Single-edge scan works only when the high-excess-gain setting is enabled. When single-edge scan is selected, the sensor
object detection size is 10 mm and edge resolution is 2.5 mm.
3.6.3 Double-Edge Scan
Double-edge scan is used to detect two edges of a single object, for example, to determine box width measurements.
Double-edge scan requires the selection of a step size: 1, 2, 4, 8, 16 or 32 beams.
The sensor uses the steps to "skip" over beams, as follows:
1. The sensor activates beam 1 (closest to the sensor display end).
2. The sensor activates the next beam, determined by the step size. (For example, if the step size is 2, beam 3 is next; if
the step size is 8, beam 9 is next.)
3. As long as the activated beam is made (unblocked), the sensor continues the stepping routine until a blocked beam is
found.
4. When a blocked beam is found, a binary search is conducted to find the object's "bottom" edge.
5. When the bottom edge is found, the sensor continues to step through the array until it finds the next unblocked beam.
6. Another binary search is performed to find the second edge.
Similar to single-edge scan, double-edge scan has some restrictions: the object should provide a solid obstruction; the size of
the object determines the maximum step size. Double-edge scan can be used to detect up to three objects. Like single-edge
scan, double-edge scan works only when the high-excess-gain setting is selected. When double-edge scan is selected, the
sensor object detection size varies, depending on the step size, but edge resolution is 2.5 mm.
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Figure 8. Double-edge scan
Emitter
Receiver
Step #1 Step #2 Step #3
Step #4 Step #5
Beam #1 of 30
blocked
Beam #15
blocked
Beam #23 clear
Beam #19 clearBeam #17
blocked
Step #6
Beam #18
blocked
3.6.4 Maximum Scan Times in SIO Mode
Table 6: Maximum scan times (in milliseconds) during SIO mode
Array Length Straight
Scan
Single-
Edge
Scan
Double-Edge Scan
Step 1 Beam Step 2 Beams Step 4 Beams Step 8 Beams Step 16
Beams
Step 32
Beams
150 mm (5.9 in) 2.8 1.5 3.4 2.8 2.5 2.4 1.9 N/A
300 mm (11.8 in) 5.0 1.5 5.9 4.1 3.2 2.8 2.3 2.1
450 mm (17.7 in) 7.1 1.6 8.5 5.5 4.2 4.0 3.2 2.5
600 mm (23.6 in) 9.3 1.6 11.0 6.8 4.9 4.2 4.0 2.8
750 mm (29.5 in) 11.4 1.7 13.5 8.1 5.7 4.6 4.5 4.5
900 mm (35.4 in) 13.6 1.7 16.0 9.5 6.1 4.7 4.6 4.6
1050 mm (41.3 in) 15.7 1.8 18.6 10.8 6.8 5.2 4.8 4.8
1200 mm (47.2 in) 17.9 1.8 21.1 12.2 7.4 5.5 4.9 4.9
1500 mm (59.1 in) 22.2 1.9 26.1 14.8 9.0 6.4 5.3 4.9
1800 mm (70.9 in) 26.5 2.0 31.2 17.5 10.5 7.3 6.0 5.6
2100 mm (82.7 in) 30.8 2.8 36.3 20.2 12.0 8.2 6.7 5.6
2400 mm (94.5 in) 35.1 2.8 41.4 22.9 13.5 9.1 7.4 5.9
When communicating over IO-Link, there is a minimum cycle time of 18 ms for COM2. The maximum scan time will be the
greater between the SIO scan time and the IO-Link cycle time.
Scan times are also dependent on analog filter speed; see the IO-Link Data Reference Guide (p/n 220588).
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4 Installation Instructions
4.1 Mounting the Emitter and Receiver
Compact EZ-ARRAY emitters and receivers are easy to handle during mounting. When mounted to the sensor end caps, the
supplied mounting brackets allow ±30° rotation. An emitter may be separated from 400 mm to 4 m (16 in to 13 ft) from its
receiver.
From a common point of reference, make measurements to locate the emitter and receiver in the same plane, with their
midpoints and display ends directly opposite each other. (If sensors are mounted with their display ends at the top, see
Receiver Gray (Remote Teach) Wire on p. 8 or refer to HW Interface table in Configuration via DIP Switch or IO-Link v1.1
Interface on p. 8 for directions on inverting the 3-digit display.) Mount the brackets to the emitter and receiver housings using
the supplied M6 bolts and Keps nuts, or user-supplied hardware.
Center mounting brackets must be used with longer sensors, if they are subject to shock or vibration. In such situations,
the sensors are designed to be mounted with up to 900 mm unsupported distance (between brackets). Sensors 1050 mm
and longer are supplied with a center bracket to be used as needed with the standard end-cap brackets.
1. Attach the center bracket to the mounting surface when mounting the end-cap brackets.
2. Attach the clamp to both slots of the housing, using the included M5 screws and T-nuts.
3. After the sensor is mounted to the end-cap brackets, attach the clamp to the center bracket using the supplied M5
screw.
EZ-ARRAY End-Cap Brackets (supplied with each emitter and receiver) Swivel Center Bracket (supplied with emitters and
receivers 1050 mm and longer)
Figure 9. End-Mounted Figure 10. Side-Mounted (two sensor brackets
may be substituted)
Figure 11. Sensors are designed to be mounted with up
to 900 mm unsupported distance between brackets.
Note: Sensor brackets are designed to mount directly to accessory MSA series stands using the hardware
supplied with the stands.
4.2 Mechanical Alignment
Mount the emitter and receiver in their brackets and position the windows of the two units directly facing each other. Measure
from one or more reference planes (e.g., the building floor) to the same point(s) on the emitter and receiver to verify their
mechanical alignment.
Use a carpenter's level, a plumb bob, or the optional LAT-1-SS Laser Alignment Tool, or check the diagonal distances
between the sensors, to achieve mechanical alignment.
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Figure 12. Mechanical alignment
When alignment is difficult, use alignment tool LAT-1-SS to assist or confirm alignment by providing a visible red dot along
the sensor's optical axis. Snap the LAT-1 clip onto the sensor housing, turn on its laser emitter, and use a strip of
retroreflective tape at the opposite sensor to see the dot.
Also check "by eye" for line-of-sight alignment. Make any necessary final mechanical adjustments, and hand-tighten the
bracket hardware. See Optical Alignment on p. 19 and Alignment/Blanking Button (Electronic Alignment) on p. 22 for
further alignment information.
Verify that:
• The emitter and receiver are directly opposite each other, and nothing is interrupting the beams.
• The sensing area is the same distance from a common reference plane for each sensor.
• The emitter and receiver are in the same plane and are level/plumb and square to each other (vertical, horizontal,
or inclined at the same angle, and not tilted front-to-back or side-to-side).
Figure 13. Verify the emitter and receiver are in the same plane and level/square to each other
For angled or horizontal Installations, verify that:
• Distance X at the emitter and receiver are equal.
• Distance Y at the emitter and receiver are equal.
• Distance Z at the emitter and receiver are equal from parallel surfaces.
• Vertical face (i.e., the lens) is level/plumb.
• Sensing area is square. Check diagonal measurements if possible; see Figure 15 on p. 18.
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Figure 14. Angled or horizontal installations
Level Surface
X X
Emitter Receiver
level level
Y Y
ZZ
For vertical installations, verify that:
• Distance X at emitter and receiver are equal.
• Both sensors are level/plumb (check both the side and face).
• Sensing area is square. Verify diagonal measurements if possible (Diagonal A = Diagonal B).
Figure 15. Vertical installations
Level Surface
AB
level level
XX
4.3 Wiring Diagrams
Sync (Pink) Wire: The emitter and receiver are electrically synchronized via the pink wire. The emitter and receiver pink
wires must only be electrically connected together.
Inputs
Receiver gray wire—The receiver has an input that can be used as a gate input or for remote teach. To initiate remote teach,
alignment, and gating functions, tie the wire through a switch to sensor common. See Receiver Gray (Remote Teach) Wire
on p. 8 for more information.
Outputs
Analog white and yellow wires—The receiver has two analog outputs. Both outputs are voltage analog outputs. The white
wire is referenced as analog output 1; the yellow wire is referenced as analog output 2. The voltage analog outputs will
source current through an external load to sensor common.
Discrete Outputs—The receiver has two discrete outputs; the green wire is referenced as discrete output 1, and the red wire
is referenced as discrete output 2. Discrete output 1 is a push-pull output. Discrete output 2 is PNP, unless the polarity is
altered via the communication interface. Refer to Specifications on p. 27 for further electrical requirements.
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Figure 16. PNP Outputs without IO-Link Master
Receiver Emitter
wh wh
ye ye
gn
gn
rd
rd
gy 0-2V dc
gy
bare bare
pk
bu
bn
pk
bu
bn
Sync
Power Supply V+
Power Supply V-
Sync
Power Supply V+
Power Supply V-
V Out 1
V Out 2
Out 1
Out 2
Teach
Shield Shield
Load
Load
+
–
+
–
18-30V dc
Power
+
–
Figure 17. Wiring with an IO-Link Master
gn
rd*
pk
bu
bn
Sync
Power Supply V+
Power Supply V-
Sync
Power Supply V+
Power Supply V-
C/Q
Out 2*
Receiver Emitter
pk
bu
bn
2
7
6
3
8
2
1
3
4
2
7
6
Out 2*
C/QV-V+
IO-Link
Master
IO-Link
Cable
Splitter
Out 2 can be either
Discrete Output 2 or
Voltage Output 1,
depending on splitter
model
*
4.4 Optical Alignment
The objective of the optical alignment process is to adjust the emitter light level to maximize sensor performance. Perform the
alignment procedure at installation and again whenever the emitter and/or receiver is moved.
During the alignment procedure, the receiver polls each beam channel to measure excess gain and performs a gain
adjustment for each beam. When the system exits the alignment procedure, each channel's signal strength is stored in non-
volatile memory.
The procedure can be performed using the receiver remote wire, the receiver interface push button or the IO-Link v1.1
interface. (See Receiver Gray (Remote Teach) Wire on p. 8 and Alignment/Blanking Button (Electronic Alignment) on p.
22.) The receiver's Alignment push button may be disabled, by configuration thru the IO-Link v1.1 interface.
1. After the electrical connections are made, power up the emitter and receiver.
2. Verify that input power is present to both emitter and receiver; the emitter Status indicator and the receiver Status
LED should be ON green. If the receiver Status LED is on red (and a "c" appears on the 3-digit display), refer to the
error codes. (Error Codes on p. 26)
Note: At power-up, all Zone indicators are tested (flash red), then the number of blocked beams is
displayed.
3. Observe the receiver indicators.
4. Optimize Alignment and Maximize Excess Gain:
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a. Verify that the emitter and receiver are pointed squarely at each other. A straightedge or level can help
determine the direction the sensor is facing.
b. Slightly loosen the sensor mounting screws and rotate one sensor to the left and right, noting the positions
where the receiver Zone indicators turn from green to red; repeat with the other sensor.
c. Center each sensor between the noted positions and tighten the end cap mounting screws, making sure to
maintain the positioning. The sensor windows should directly face each other.
5. After optimum optical alignment is verified, proceed to configuration, via the remote teach wire, the receiver interface,
or the IO-Link v1.1 interface ( Receiver Gray (Remote Teach) Wire on p. 8, Alignment/Blanking Button (Electronic
Alignment) on p. 22, or refer to the Alignment/Blanking Button (Electronic Alignment) on p. 22) and complete the
electronic alignment. This further alignment step adjusts the emitted light level of each beam for the application, to
maximize sensing performance.
Figure 18. Optical alignment
Straightedge
Straightedge
a)
b)
c)
d)
0 beams blocked; all Zone indicators ON Green
60 beams blocked; all Zone indicators ON Red
30 beams blocked; 4 Zone indicators ON Green, 3 ON Red
0 beams blocked; all Zone indicators ON Green
Table 7: Receiver interface indicators during alignment
All Beams Either Clear or Blanked Some Beams Blocked or Mis-
Aligned Out of Alignment
Zone Indicators All ON Green
Some ON Red (zones with blocked
beams) Some ON Green (zones with
all clear beams)
All ON Red (Some beams blocked in
each zone)
Receiver Status Indicator ON Green ON Green ON Green
3-Digit Display 0 (Number of blocked beams) Number of blocked beams Total number of beams in the array
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