Banner A-GAGE High-Resolution MINI-ARRAY MAHE6A User manual

A-GAGE®High-Resolution MINI-ARRAY®
Instruction Manual
Original Instructions
64118 Rev. D
30 August 2019
©Banner Engineering Corp. All rights reserved
64118

Contents
1 Product Description ........................................................................................................................................................3
1.1 Emitter and Receiver Models ..........................................................................................................................................................3
1.2 Control Module Models .................................................................................................................................................................. 4
2 System Overview ............................................................................................................................................................5
2.1 System Features ............................................................................................................................................................................. 5
2.2 Supplied System Software ............................................................................................................................................................. 6
2.3 Typical Applications ........................................................................................................................................................................6
3 Installation Instructions ...................................................................................................................................................8
3.1 Emitter and Receiver Mounting ...................................................................................................................................................... 8
3.2 Control Module Mounting ............................................................................................................................................................... 9
3.3 Wiring ..............................................................................................................................................................................................9
3.3.1 Emitter and Receiver Wiring ..................................................................................................................................................10
3.3.2 Inputs .....................................................................................................................................................................................10
3.3.3 Outputs ..................................................................................................................................................................................11
3.4 Install the Software ....................................................................................................................................................................... 11
4 Control Module Configuration ...................................................................................................................................... 13
4.1 Communications Setup ................................................................................................................................................................ 13
4.1.1 Ping Routine .......................................................................................................................................................................... 13
4.1.2 Factory Settings .................................................................................................................................................................... 14
4.2 System Alignment .........................................................................................................................................................................14
4.2.1 Push-Button Alignment Routine ............................................................................................................................................14
4.2.2 Software Alignment Routine ..................................................................................................................................................14
4.2.3 Blanking .................................................................................................................................................................................15
4.3 Programming Control Module Response ..................................................................................................................................... 17
4.3.1 Selected Controller and Serial Communication .................................................................................................................... 18
4.3.2 Control Mode Selection .........................................................................................................................................................19
4.3.3 Scanning Method .................................................................................................................................................................. 19
4.3.4 Scan Analysis Mode Selection ..............................................................................................................................................22
4.3.5 Analog Output Configuration (Analysis Mode Assignment) .................................................................................................. 22
4.3.6 Zero Value ............................................................................................................................................................................. 23
4.3.7 Discrete Output Configuration (Analysis Mode Assignment) ................................................................................................ 23
4.4 Serial Communication with a Host Controller ...............................................................................................................................24
4.4.1 Serial Data Transmission .......................................................................................................................................................24
4.4.2 Transmission Type ................................................................................................................................................................ 25
4.4.3 Serial Options ........................................................................................................................................................................25
4.5 Transfer of PSF to the Control Module .........................................................................................................................................25
4.5.1 Saving and Recalling PSF Files .............................................................................................................................................25
4.5.2 PSF Output Analysis ............................................................................................................................................................. 25
4.5.3 Quit and Exit ..........................................................................................................................................................................26
5 System Diagnostics ......................................................................................................................................................27
5.1 Diagnostic Indicators .................................................................................................................................................................... 27
5.2 Diagnostics Routine ......................................................................................................................................................................28
6 Specifications ............................................................................................................................................................... 29
6.1 Emitter and Receiver Specifications .............................................................................................................................................29
6.2 Emitter and Receiver Dimensions .................................................................................................................................................30
6.3 Emitter/Receiver Mounting Bracket Dimensions .......................................................................................................................... 31
6.4 Control Module Specifications ..................................................................................................................................................... 31
6.5 Control Module Dimensions ......................................................................................................................................................... 33
7 Accessories ................................................................................................................................................................... 34
7.1 Cordsets ........................................................................................................................................................................................ 34
8 Additional Information .................................................................................................................................................. 35
8.1 Host Mode Command String ........................................................................................................................................................35
8.2 Serial Data Format and Header String ..........................................................................................................................................35
8.2.1 ASCII Format Data Transmission .......................................................................................................................................... 35
8.2.2 Binary Format Data Transmission ......................................................................................................................................... 36
8.3 Max Meas Mode Command String ...............................................................................................................................................37
8.4 Glossary ........................................................................................................................................................................................38
9 Product Support and Maintenance .............................................................................................................................. 39
9.1 Contact Us .....................................................................................................................................................................................39
9.2 Banner Engineering Corp Limited Warranty ................................................................................................................................. 39
A-GAGE®High-Resolution MINI-ARRAY®

1 Product Description
For Controllers with 2 Analog and 2 Discrete Outputs
• Excels at high-speed, precise process monitoring and inspection
applications
• A comprehensive combination of scanning modes and outputs:
◦10 measurement (Scan Analysis) modes
◦3 scanning methods
◦Beam blanking
◦Selectable continuous, gated or host-controlled scan initiation
◦Programmable hysteresis for high and low limits
◦Serial communication options
• Storable scanning programs eliminate reprogramming for repeated
applications
• Non-volatile memory stores alignment settings
• All models with both Analog and Discrete outputs
• Analog output Null setting
• Low cost, compared with similar systems
• Precision sensors have a 380 mm to 1.8 m (15 in to 6 ft) working range
• Wide field of view, easily aligned
• Alignment routine equalizes gain of each beam for reliable 2.5 mm (0.10 in)
object detection throughout the array
• Host computer or PLC may be used to initiate scans and/or process scan
data
• Unique addresses for up to 15 control modules on one EIA-485 Party Line
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.
1.1 Emitter and Receiver Models
Emitter Model Receiver Model Array Length Y Total Beams
MAHE6A Emitter MAHR6A Receiver 163 mm (6.4 in) 64
MAHE13A Emitter MAHR13A Receiver 325 mm (12.8 in) 128
MAHE19A Emitter MAHR19A Receiver 488 mm (19.2 in) 192
MAHE26A Emitter MAHR26A Receiver 650 mm (25.6 in) 256
MAHE32A Emitter MAHR32A Receiver 813 mm (32.0 in) 320
MAHE38A Emitter MAHR38A Receiver 975 mm (38.4 in) 384
MAHE45A Emitter MAHR45A Receiver 1138 mm (44.8 in) 448
MAHE51A Emitter MAHR51A Receiver 1300 mm (51.2 in) 512
MAHE58A Emitter MAHR58A Receiver 1463 mm (57.6 in) 576
MAHE64A Emitter MAHR64A Receiver 1626 mm (64.0 in) 640
MAHE70A Emitter MAHR70A Receiver 1788 mm (70.4 in) 704
MAHE77A Emitter MAHR77A Receiver 1951 mm (76.8 in) 768
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1.2 Control Module Models
Controller Model Solid-State Discrete Outputs Analog Outputs
MAHCVP-1 2 PNP (2) 0 V to 10 V Sourcing
MAHCVN-1 2 NPN (2) 0 V to 10 V Sourcing
MAHCIP-1 2 PNP (2) 4 mA to 20 mA Sinking
MAHCIN-1 2 NPN (2) 4 mA to 20 mA Sinking
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2 System Overview
The A-GAGE®High-Resolution 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 and similar
uses.
A typical A-GAGE High-Resolution MINI-ARRAY system has five components: a high-resolution emitter/receiver pair, each
with quick-disconnect (QD) connectors; one of four compact control modules; and quick-disconnect cables to connect
them. Software is included to interface any PC-compatible computer (running Windows®1XP, Vista, or 7) with the control
module for system configuration. A host computer or PLC may be used to control and/or receive input from the system.
Sensors are available in twelve array lengths from 163 mm to 1951 mm (6.4 in to 76.8 in), in 163 mm (6.4 in) increments. The
emitter has two columns of infrared LEDs spaced 5 mm (0.2 in) apart. The columns are separated by 7.5 mm (0.3 in) and are
staggered from each other by 2.5 mm (0.1 in). The receiver is configured opposite to the emitter, with the identical length
and beam spacing. This high-resolution sensor pair is capable of detecting a 12.7-mm long by 2.54-mm diameter (0.5 in by
0.1 in diameter) cylindrical rod (held perpendicular to the sensor). The sensors have a wide field of view and are easily
aligned, with a working range of 380 mm to 1.8 m (15 in to 6 ft).
Each of the four versatile microcontroller-based control modules are configured using a PC-compatible computer running
Windows XP, Vista, or 7, and the supplied software, via the built-in RS-232 interface.
2.1 System Features
Built-in features simplify the operation of the A-GAGE High-Resolution MINI-ARRAY system. High-resolution emitters and
receivers, available in twelve lengths, feature two closely spaced columns of beams to provide a precise, high-resolution
light screen for exacting applications. The Alignment routine automatically equalizes the excess gain of each beam for
reliable 2.5-mm (0.10-in) object detection throughout the array and stores this data in non-volatile memory. The Alignment
routine does not need to be performed again unless the sensing application changes, or if the emitter and/or receiver is
moved. Programmable beam blanking accommodates machine components or other fixtures that must remain in or move
through the light screen. Blanking may be set automatically as part of the initial setup, or by using the included
configuration software.
Built-in diagnostic programming and easy-to-see indicators on the sensors and the control module make alignment and
troubleshooting easy. 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 four status indicators: 3 red LEDs signal discrete output #1 conducting, Alarm output
(discrete output #2) conducting, and gate signal received; a green LED signals that the sensors are properly aligned. A
segmented LED Diagnostics Indicator provides detailed system status using single-digit codes; a period in the indicator
window indicates the presence of blanking. A key to the diagnostics codes is printed on the side of the control module for
simplified troubleshooting.
The A-GAGE High-Resolution 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. Up to 15
systems may be networked.
1Microsoft and Windows are registered trademarks of Microsoft Corporation in the United States and/or other countries.
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High-Resolution Emitter
DIN-Rail-Mountable Control Module
High-Resolution Receiver
HIGH RESOLUTION MINI-ARRAY CONTROLLER
ALIGNMENT
SWITCH
POWER
POWER
DIAGNOSTICS
INDICATOR
2 - TX
3 - RX
5 - COM
RS-232
MAHCVP-1
OUTPUT ALARM GATE ALIGN
1
+ –
+–
16-30V dc
1A MAX
10-30VDC
GATE
D OUT 1
150mA MAX
0-10VOLTS
25mA (MAX)
V OUT 1
EMTR RCVR
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1 +12V COM DRN T/R T/R
BR BU BK WH
TX TX
+–
10-30VDC
ALIGN
0-10VOLTS
25mA (MAX)
V OUT 2
+V
ALARM
150mA MAX
+V
7.6 mm (0.30")
2.5 mm
(0.10")
5.1 mm
(0.20")
Diagnostics Indicator
Alignment Button
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
Figure 1. A-GAGE High-Resolution MINI-ARRAY System Features
2.2 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.
2.3 Typical Applications
Figure 2. Log Profiling for Lumber Optimization Figure 3. Box Profiling
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Figure 4. Maintaining Center of Opaque Rolled Goods Figure 5. Inspection Applications
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3 Installation Instructions
3.1 Emitter and Receiver Mounting
Banner MINI-ARRAY emitters and receivers are small, lightweight, and easy to handle during mounting. The mounting
brackets (supplied) allow ±30° rotation.
From a common point of reference, make measurements to locate the emitter and receiver in the same plane with their
midpoints directly opposite each other. Mount the emitter and receiver brackets using the vibration isolators and M4 Keps
nuts (all supplied). Standard M4 or #8-32 bolts may be substituted (and the vibration isolators eliminated) in situations
where the emitter and receiver are not subjected to shock or vibration forces. While the internal circuits of the emitter and
receiver are able to withstand heavy impulse forces, the vibration isolators dampen impulse forces and prevent possible
damage due to resonant vibration of the emitter or receiver assembly.
M4 x 10 mm
Slotted Hex Head
with Compression
Washer (2)
Mounting
Bracket
Mounting
Surface
Emitter or
receiver
M4 Keps
Nut (8)
Anti-Vibration
Mount (4)
Studs: M4 x 0.7
9.5 mm (0.38") long Mounting
Bracket
Washer
Nut
Figure 6. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting hardware
1. Mount the emitter and receiver in their mounting brackets; see Figure 6 (p. 8).
2. Position the red lenses of the two units directly facing each other. The connector ends of both sensors must point in
the same direction.
3. Measure from one or more reference planes (for example, 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.
4. Also check by eye for line-of-sight alignment.
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5. Make any necessary final mechanical adjustments, and hand-tighten the bracket hardware.
6. See System Diagnostics (p. 27) for information on alignment indicators and Control Module Configuration (p. 13)
for information on the use of the alignment software which is supplied with the controller.
3.2 Control Module Mounting
Install the controller inside an enclosure with a NEMA (or IEC) rating suitable for the operating environment. Mounting
dimensions for the controller are shown in Control Module Dimensions (p. 33). The controller is supplied with M3.5
hardware for direct mounting to a surface, or it can be mounted onto standard 35 mm DIN rail.
3.3 Wiring
Refer to the following figures for the appropriate wiring information.
POWER
1
+ –
+–
16-30V dc
1 A max
10-30V dc
GATE
SIGNAL
+30V dc max
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
DISCRETE
OUTPUT#1
150 mA
max
EMITTER and
RECEIVER CABLES
TX TX
DISCRETE
OUTPUT#2 (ALARM)
+–
10-30V dc
ALIGN
RS-485
+30V dc max
150 mA
max
25 mA
max
0-10V
ANALOG
OUTPUT #2
25 mA
max
0-10V
ANALOG
OUTPUT #1
Figure 7. MAHCVN-1 Wiring
POWER
1
+ –
+–
16-30V dc
1 A max
10-30V dc
GATE
SIGNAL
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
DISCRETE
OUTPUT#1
EMITTER and
RECEIVER CABLES
TX TX
+–
10-30V dc
ALIGN
RS-485
150 mA
max
25 mA
max
0-10V
ANALOG
OUTPUT #2
25 mA
max
0-10V
ANALOG
OUTPUT #1
DISCRETE
OUTPUT#2 (ALARM)
150 mA
max
Figure 8. MAHCVP-1 Wiring
+30V dc max
POWER
1
+ –
+–
16-30V dc
1 A max
10-30V dc
GATE
SIGNAL
+30V dc
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
DISCRETE
OUTPUT#2 (ALARM)
DISCRETE
OUTPUT#1
+–
10-30V dc
ALIGN
Load
+16-30V
4-20 mA
ANALOG
OUTPUT#2
4-20 mA
ANALOG
OUTPUT#1
+16-30V
150 mA
max
150 mA
max
TX TX
RS-485
Load
Figure 9. MAHCIN-1 Wiring
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+16 – 30V dc
+16 – 30V dc
POWER
1
+ –
+–
16-30V dc
1 A max
10-30V dc
GATE
SIGNAL
4-20 mA
ANALOG
OUTPUT #1
4-20 mA
ANALOG
OUTPUT #2
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F1
BROWN BLUE DRAIN (BARE) BLACK WHITE
EMITTER and
RECEIVER CABLES
DISCRETE
OUTPUT#2 (ALARM)
+–
10-30V dc
ALIGN
Load Load
150 mA
max
DISCRETE
OUTPUT#1
150 mA
max
TX TX
RS-485
Figure 10. MAHCIP-1 Wiring
3.3.1 Emitter and Receiver Wiring
Connect emitters and receivers together in parallel to terminals #4 through #8 of the control module (identical for all control
module models). See the figures in
Wiring (p. 9) for wire color information.
Trim braided shield flush
with cable
Trim foil shield flush
with cable
Uninsulated
drain wire
Note: The “drain wire” is the
uninsulated stranded wire which runs
between the braided shield and the
foil shield. The foil shield and the
braided shield should be removed at
the point where the wires exit the
cable.
Figure 11. Emitter and Receiver Cable Preparation
3.3.2 Inputs
System Power: Connect a source of 16 V dc to 30 V dc, rated at 1 amp or greater, to control module terminals #1 (+) and #2
(-). Connect a good earth ground to terminal #3 to provide electrical and RF noise immunity to the System.
Note: Remove power before making other connections to the controller.
Gate Signal: A source of 10 V dc to 30 V dc switched to terminals #12(+) and #13(-) provides a gating input (if required). The
gating voltage typically is switched by the open-collector output transistor of a dc sensing device. The gate signal controls
scanning when one of four Gate options is selected in the Control Mode Selection menu of the PSF configuration routine
(see Control Mode Selection (p. 19)) .
Align: A source of 10 V dc to 30 V dc switched to terminals #14(+) and #15(-) provides a remote means of running the
automatic alignment and blanking routines. The switch sequence is identical to the procedure described in
Push-Button
Alignment Routine (p. 14) for the Alignment switch on the front of the control module.
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3.3.3 Outputs
Control Module Analog Outputs (Terminals #10 and 16) Discrete Outputs2(Terminals #9 and
20)
MAHCVN-1
Figure 7 (p. 9)
0 V to 10 V Sourcing
15 mA maximum
NPN open-collector
30 V dc maximum
150 mA maximum
MAHCVP-1
Figure 8 (p. 9)
0 V to 10 V Sourcing
15 mA maximum
PNP open-collector
30 V dc maximum
MAHCIN-1
Figure 9 (p. 9)
4 mA to 20 mA
Sinking
16 V dc to 30 V dc
NPN open-collector
30 V dc maximum
150 mA maximum
MAHCIP-1
Figure 10 (p. 10)
4 mA to 20 mA
Sinking
16 V dc to 30 V dc
PNP open-collector
30 V dc maximum
150 mA maximum
Serial Communication
RS-232: All A-GAGE High-Resolution MINI-ARRAY Systems may communicate with a host computer or controller via
RS-232 or RS-485 serial protocol. See Section 5.3.1 for selectable communications parameters. Prepare an RS-232 cable
using a male DB-9 connector with connections as shown.
Note: DO NOT use a “null modem” RS-232 cable
2 - TX
3 - RX
5 - COM
RS-232
5 3 2
DB-9 Pin # Function
2 Transmit (TX)
3 Receive (RX)
5 Ground (GND)
Figure 12. DB-9 connections between the control module and the PC
RS-485: RS-485 serial port is located at terminals #18 (TX) and #19 (TX).
3.4 Install the Software
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 from www.bannerengineering.com
as required.
2Discrete Output #2 is labeled Alarm on the control module.
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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. The Welcome dialog box displays. Select Next, and follow the prompts in the dialog boxes as they appear.
• If the program does auto-start, the Welcome dialog box appears. Select Next, and follow the prompts in the
dialog boxes as they appear.
3. The installation program decompresses the files. A status dialog box monitors the progress of the installation.
4. An Installation Completed dialog box appears. Select OK.
5. 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 the MINI-
ARRAY icon to launch the program, then follow the configuration instructions.
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4 Control Module Configuration
Configure the A-GAGE High-Resolution MINI-ARRAY control module using a Windows®menu-style routine; the
configuration routine requires the Banner-supplied HRMA software and a PC-compatible computer (running Windows®XP,
Vista, or 7). Make a serial data connection between the computer and the DB9 connector on the control module.
4.1 Communications Setup
1. After installing the software, attach the serial communication cable between the control module and the PC.
Note: If an RS-232 interface is used, only one control module is allowed on the line at any one
time.
The minimum connections to the control module’s DB-9 connector are shown in Figure 12 (p. 11).
2. Launch the High-Resolution MINI-ARRAY program.
3. Configure the serial communications port of the PC.
a) Select Options > Serial Port from the High-Resolution MINI-ARRAY main menu.
The program supports serial communication via the COM1-COM20.port of the computer.
b) Highlight the desired serial port to select it.
c) Select Save Settings on Exit to store the serial port selection, if it is not already ON.
Parity is selected here also: Even, Odd or None.
4.1.1 Ping Routine
Perform the Ping routine during system configuration, and before any Diagnostic, Alignment, or Edit routine. The routine
polls all control modules on the communications line (one, in the case of the standard RS-232 line, or up to 15 modules, on
an RS-485 circuit). It then is used to select an individual control module for configuration or alignment.
1. If needed, apply power to the system control module and allow the system to complete its power-up routine.
2. Press F5 or access the MINI-ARRAY menu.
3. Select Ping to perform the Ping routine.
All connected control modules identify themselves with an ID value and baud rate; the routine takes approximately
15 to 20 seconds. After the Ping is performed, all valid control module ID values display in a chart on the screen,
under their appropriate baud rates. Control modules are identified in the chart as X.
Figure 13. Screen showing the result of a completed Ping routine
4. Point to a valid ID and click to select a control module.
System Diagnostics, Alignment, or Edit routines may now be performed for the selected control module.
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4.1.2 Factory Settings
Of the 15 available control module ID values (A through O), the factory software setting is A. Selectable communication
baud rates are 9600, 19200, and 38400; the factory setting is 9600. See Selected Controller and Serial Communication (p.
18) for information on changing these settings.
4.2 System Alignment
The emitter/receiver pairs have a wide field of view and are easy to align. The recommended distance between the emitter
and receiver ranges from 380 mm to 1829 mm (15 in to 72 in). Shorter sensor separation can be achieved; consult Banner
Engineering for details.
Perform the Alignment process at System installation and repeat it every time one or both of the sensors is moved.
Alignment of the System can be specified automatically using either the Alignment routine of the configuration software or
the Alignment switch on the control module’s front panel.
The System also may be aligned remotely, using pins 14 and 15 on the terminal block. Apply 10 V dc to 30 V dc power to
the pins to approximate the push-button procedure. For example, apply input signal for 3 seconds to access Alignment
mode.
1. Make sure the sensors have been wired as shown in
Wiring (p. 9).
2. Apply power to the control module via terminals #1 and #2 (16 V dc to 30 V dc).
The Diagnostics Indicator shows the sensors going though a power-up test: first the receiver, then the emitter. After
the sensors have been tested and the System is ready for service, the Diagnostics Indicator shows —or —.; see
figure.
ALIGNMENT
SWITCH
R
DIAGNOSTICS
INDICATOR
OUTPUT ALARM GATE ALIGN
150mA MAX
EMTR RCVR
ALIGNMENT
SWITCH
R
DIAGNOSTICS
INDICATOR
OUTPUT ALARM GATE ALIGN
150mA MAX
EMTR RCVR
With Blanking OFF With Blanking ON
Denotes
Blanking
Figure 14. Diagnostics Indicator Showing a Clear Condition
4.2.1 Push-Button Alignment Routine
Re-align the System at installation or whenever the emitter and/or receiver is moved.
1. Press the Alignment switch on the control module front panel for 3 seconds.
The letter Adisplays on the Diagnostics Indicator; the System is learning a clear condition.
2. Rotate the sensors as required (but do not change the distance between them).
When the green Alignment LED is displayed on the control module and receiver, the sensors are adequately aligned.
3. To leave Alignment mode, press the Alignment switch for 3 seconds.
During the alignment procedure, the System polls each receiver channel to measure excess gain and performs a coarse
gain adjustment. When the System exits the alignment procedure, each channel’s signal strength is stored in non-volatile
memory. The System is now ready for operation and does not require re-alignment unless the emitter or receiver is moved.
4.2.2 Software Alignment Routine
The green LED indicator on the receiver and also on the control module continuously displays Alignment status. When all
unblanked beams are clear, the green Alignment indicators are ON. To better understand blocked, clear, and blanked
beams, launch the Alignment routine (press F8 or select Alignment under the MINI-ARRAY menu). The screen shows the
state of all of the beam channels, grouped into sets of 16.
Key information provided on the Alignment screen is the sensor size, plus the number of beams blocked, made, and
blanked. The sensor size is given the title of Total; this refers to the total number of beam channels in the array. The number
of beams blocked is a running total of blocked beams, excluding any blanked beams. The Made value is a count of
unblocked beams. The Blanked value is a count of the number of beam channels that are blanked (channels that are
ignored for measurement mode applications).
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The Alignment screen provides the following functions: Start, Stop, Step, Clear Blanking Fields, Restore Control module
Settings, Auto Blanking, Abort Auto Blanking, Save to File, Read From File, Cancel, OK, and Edit. To access any of these
sub-routines, first click Stop, then the selected option.
Start causes the control module to continuously scan and report All Channel Data. This data is used to update the state of
each beam channel.
Stop causes the control module to stop scanning.
Step produces one scan and then stops until another command is issued.
Clear Blanking Fields is a quick way to remove blanking specifications.
Restore Control Module Settings recalls the blanking specifications in effect prior to Alignment/Blanking being entered.
Auto Blanking is used to scan and determine which beams are blocked; blocked beams automatically become blanked
beams. The Auto Blanking values can then be Accepted or Aborted.
Edit is used to control the blanking specifications of any channel manually. This is useful for adding any number of blanked
beam channels above and/or below a blanked object to allow for vibration or other movement of the object to be ignored.
Blanking specifications can be saved and read from a computer file using Save To File and Read From File commands.
Figure 15. Alignment screen
4.2.3 Blanking
If a machine fixture or other equipment will continuously block one or more beams, the affected beam channels may be
blanked. The Blanking option causes the control module to ignore the status of blanked beams for measurement mode
calculations. For example, if a machine fixture blocks one or more beams during System operation, the output data will be
incorrect; if beams blocked by the fixture are blanked, the output data will be correct. Blanking may be configured using the
push-button Alignment switch on the control module, or by using the System software and a computer.
Push-Button Blanking Setup Routine
To specify blanking using the control module’s Alignment switch, position the object or part to be ignored in the path of the
beams before beginning the Alignment routine.
1. Press the Alignment switch for 3 seconds.
The Diagnostics Indicator shows the letter A.
2. Press the Alignment switch momentarily (about 0.5 seconds maximum).
The Diagnostics Indicator shows the letter bto indicate it is ready to learn the blanking pattern.
3. Press the Alignment switch momentarily (about 0.5 seconds maximum) to set the blanking fields.
Both the control module and the receiver indicate a clear condition (green Align indicator ON) and the Diagnostics
Indicator shows A. (the period following the A indicates that blanking is in use). The beams blocked during the
routine are now blanked.
4. To return to Run mode, again press the Alignment switch for 3 seconds.
When the System is ready for operation and configured for beams to be blanked, the period on the Diagnostics
Indicator remains lit, showing —..
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System Software Blanking Setup Routine
1. Position the object to be blanked in the path of the beams (this can be done at any time before beginning the
blanking routine).
2. Perform the Ping routine to select the proper control module.
3. Press F8 or select the Alignment option from the MINI-ARRAY menu.
4. From the screen menu, select Stop.
The Diagnostics Indicator on the control module shows the letter A.
5. Select Auto Blanking.
The Diagnostics Indicator shows the letter b.
6. Select Accept Auto Blanking.
Both the control module and the receiver indicate a clear condition (green Align indicator ON) and the Diagnostics
Indicator shows A. (the period following the A indicates that blanking is in use). The beams blocked during the
routine are now blanked and appear as the letter Bon the grid instead of 0.
Figure 16. Alignment screen, showing beams #1-11 blocked Figure 17. Alignment screen, showing beams #1-11 blanked
7. To blank additional beams, use Edit to manually set additional blanking (see Scanning Mode Limitations for Blanking
(p. 16)).
8. To leave Alignment mode, click OK.
When the System is ready for operation and configured for beams to be blanked, the period on the Diagnostics
Indicator will remain lit, showing —..
Scanning Mode Limitations for Blanking
All blanking features are available with Continuous Scan mode. For single-and double-edge scan, blanking is limited to four
blanking fields. Other blanking features are ignored.
To accommodate parts or components that will move through the array, blanking may be manually adjusted for one or more
individual beam channels.
1. After using the system software to specify blanking, select Edit from the Alignment screen.
The Diagnostics Indicator continues to show the letter band a grid displays on the computer screen. The beams are
numbered from the sensors’ cabled ends, with the beam closest to the cable being beam #1.
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Figure 18. Edit channel blank state screen, showing beam #22 and beams #35-42 blanked; beams #65-80 are highlighted, ready to be selected
for blanking
2. To set the blanking fields, click each grid box representing a beam you wish to blank.
3. Clicking again on a blanked beam channel removes the blanking specification.
4. To select or clear the blanking specification for several rows of channels, place the cursor directly to the left of the
row to be selected and click the mouse. The rows highlight.
5. Select Blank Selected (to accept the blanking status) or Clear Selected (to reject the blanking status) option.
6. To leave Alignment mode, click OK.
Both the control module and the receiver indicate a clear condition (green Align indicator ON) and the Diagnostics
Indicator shows A.. When the system is ready for operation and configured for beams to be blanked, the period on
the Diagnostics Indicator remains lit, showing —..
4.3 Programming Control Module Response
Use the Parameter Setup File (PSF) Configuration routine to configure the control module for a specific application. After
performing the Ping routine to select a control module, access the PSF Configuration screen by selecting Edit PSF (F4) from
the MINI-ARRAY menu. The Edit PSF process may also be performed with no control module selected, to configure and
save a PSF for multiple control modules. In such a case, some fields on the PSF Configuration screen will not be
accessible.
The process of configuring the control module involves selecting among options for each of the parameters listed in this
section, including serial communication, control mode, scanning method, scan analysis mode, serial transmission, and
analog/discrete outputs. The resulting combination of options causes the control module to react as required for the
application, to changes in the light screen.
The configuration process produces a Parameter Setup File (PSF). PSF files may be saved and retrieved as computer files
via File Save PSF and File Retrieve PSF (see Saving and Recalling PSF Files (p. 25)) . After it is configured, a PSF may be
sent to the control module via the Send PSF command. The PSF currently loaded into the control module may be displayed
by using the Upload PSF command.
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Serial Transmission
Specifies the type of data transmitted
from the control module to its host
after each scan.
Measurement Mode Result: Data
transmitted will reflect the Analysis
Mode selections.
All Mode: Transmits all data.
Max. Meas. Mode: Sends only the largest
measurement in each measuring event,
to decrease transmission size and speed
response. Choose to send when the
array is clear or send at the host’s
request.
Transmission Type: ASCII or Binary,
defines the format in which the data
will be sent.
Serial Options: Suppress Clear Data
or Suppress Header to decrease
transmission size and speed response.
Analysis (Measurement)
Mode Selection
Choose the measurement
option that best tells you
the size and/or position
of objects as they
relate to the array.
Control Mode Selection
Continuous Mode: The control
module constantly polls
the array for status.
Host Mode: The control module
polls the array for status when
prompted by a host controller.
Gate Mode: The control module
polls the array for status when
prompted by an input from a
Gate sensor.
Scanning Method
Straight scan polls each beam
sequentially to determine the
target object’s overall size. This is
the most accurate and precise
measurement, but also the most
time-consuming.
Single Edge scan requires the
target object to block beam 1
(closest to the sensors’ cabled
ends), then conducts a time-saving
binary search to “hunt” for the
target’s overall height (one
variable edge).
Double Edge scan conducts a
time-saving search of the entire
array to “hunt” for the target’s
Set Point and
Hysteresis Selection
Assigns the set point to
determine where within
the array the output(s)
will respond and
hysteresis values to
smooth output response.
Trigger/Trigger Channel Number
May be used to trigger (or gate) the scan sequence of another
A-GAGE High-Resolution MINI-ARRAY controller; in straight
scanning mode, it defines when during each scan discrete Output
#2 will change state.
Scan #: (1-9) Analog outputs are
updated with an average value of the
data received during the selected
number of scans; discrete outputs
respond only if the received data is
identical for all of the selected number
of consecutive scans.
Analog and Discrete
Output Assignment
Assigns an analysis
(measurement) mode
to each output.
Alarm: Causes the control module to
turn on discrete Output #2 whenever
the System detects a sensing error or
if the optical signal becomes marginal.
Selected Controller
Identifies the specific
control module being
configured.
Serial Communication
Changes the
identification
and baud rate of the
controller being configured.
Zero Value
Zero Value is used to specify the
analog output when the
measurement mode value is
zero. The user can specify a
value of LAST, NULL, or SPAN.
LAST: Output holds the last non-zero value before the
light screen became clear.
NULL: Provides the minimum value.
SPAN: Provides the maximum value.
overall width (two variable edges)
Figure 19. Use the PSF Configuration Screen to Program Each Control Module Individually
4.3.1 Selected Controller and Serial Communication
The Selected Controller box displays information about the control module being configured. Two of these settings may be
changed in the Serial Communication box. The settings selected and displayed in these boxes are those used to identify
the control module during the Ping routine.
Controller ID (assigned a letter, Athrough O) is used to identify each individual control module when multiple discrete-
output control modules (up to 15) are connected on one EIA-485 party line.
Note: Analog output control modules do not offer RS-485 communication; choose any ID letter (A
through O) when programming an analog-output control module.
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Baud Rate is the data communication rate between the control module and the computer used for configuration and also
the process controller. Choose from three values: 9600, 19200, and 38400.
Parity: Select Odd, Even, or None. All controllers on one EIA-485 party line should have the same parity settings.
4.3.2 Control Mode Selection
The control mode determines the method used to control scanning of the light screen array. Choose from three main
control modes:
• Continuous Scan Mode
• Serial Host Command Mode
• Gate Mode, which has four options
In Continuous Scan mode, the control module begins a new scan as soon as it updates the outputs from the previous scan.
This is the fastest scan control method; it is used in most analog output applications and whenever continuous updating of
the outputs is acceptable.
Host mode allows the control module to communicate with a host computer or control module via RS-232 (all models) or
RS-485 (discrete-output models only) serial protocol. The host directs the control module to scan on demand and receives
the output data from the control module in binary or ASCII form. Baud rates of 9600, 19200, and 38400 are selectable in the
Serial communications menu. See
Additional Information (p. 35) for more information on Host mode data format.
Gate mode activates an optically isolated external Gate input between terminals 12 (+) and 13 (-) of the control module. The
Gate input has impedance of 7.5 kΩ and accepts a 10 V dc to 30 V dc signal. A dc device such as a photoelectric sensor or
optical encoder typically supplies the Gate input. Gate input signals must be greater than 150 microseconds in duration; the
time between successive Gate inputs must be greater than the minimum scan time for the light screen array (see
Scanning
Method (p. 19) for scan time information).
Gate mode has four options:
•Gate ON: the control module will scan as long as the gate is active.
•Gate OFF: the control module will scan whenever the gate is not active.
•Gate ON/OFF: the control module will scan once for each gate transition from ON to OFF.
•Gate OFF/ON: the control module will scan once for each gate transition from OFF to ON.
4.3.3 Scanning Method
The control module may be configured for one of three scanning methods:
• Straight Scan
• Single-Edge Scan
• Double-Edge Scan
Straight scan is the default mode in which all beams are scanned in sequence from the bottom end (cable end) to the top
end of the array. This scanning method requires the longest scan times and provides the smallest object detection size (2.5
mm, 0.1 in diameter).
Single-Edge scan is used to measure the height of a single object. A good application for this scanning method is box
height measurement. For Single-Edge scan, the system always activates the first beam channel (nearest the cable end, or
bottom). If the first beam is blocked, the sensor performs a binary search to hunt for the last beam blocked. Single-Edge
scan works as follows:
1. The receiver scans only the bottom beam until that beam is blocked.
2. When the bottom 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. This is called a binary search.
4. This routine continues to narrow the field until the edge is found.
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DIAGNOSTICS
Error No. Error Type Error No. Error Type
—System OK 4Emitter Error
1Align / blank 5Serial Comm
2Output Short 6EEPROM
3E / R Mismatch 7CPU Error
4Receiver Error 8Null / Span
1
POWER
2 - TX
3 - RX
5 - COM
ALIGNMENT
SWITCH
DIAGNOSTICS
INDICATOR RS-232
MAHCN-1
HIGH RESOLUTION MINI-ARRAY CONTROLLER
2345678910 11 12 13 14 15 16 17 18 19 20
1
+
NC NC
10-30Vdc
GATE
NC
TX TX
+12V
BR
EMTR RCVR
BU BK
5 Wires
WH
30V
150mA MAX
OUTPUT#1
COMDRN T/R T/R
16-30V dc
1A MAX
POWER
2345678910 11 12 13 14 15 16 17 18 19 20
OUTPUT
ALARM
GATE
ALIGN
–
+–
F1
30V(MAX)
150mA MAX
ALARM
10-30Vdc
ALIGN RS-485
+–
High-Resolution
Emitter
MAHCN-1
Control Module High-Resolution
Receiver
Beam #1 of 64
Blocked
Beam #48
Clear
Beam #32
Blocked
Beam #44
Clear
Beam #40
Blocked
Beam #42
Blocked
Beam #43
Blocked
Step #2Step #1 Step #3
Step #4 Step #5 Step #6 Step #7
Figure 20. Finding an Edge Using a Binary Search
Note that the receiver always checks the bottom beam first, and only if that beam is blocked does the binary search
continue. Therefore, Single-Edge scan will not work in instances where an item that does not block the first beam is to be
measured. Single-Edge scan is also ineffective if the object does not present a continuous blocked pattern. In other words,
Single-Edge scan is used for single, solid objects that block the first beam.
Double-Edge scan is used to detect two edges of a single object, for example, box width measurements. Double-Edge
Scan requires the selection of a step size: 2, 4, 8, 16 or 32 beams. The sensor uses the steps to skip over beams. Double-
Edge scan works as follows:
1. The sensor activates beam #1 (the beam closest to the sensor cable 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 unblocked (or made), 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 begins stepping again through the array until the sensor finds the next
unblocked beam.
6. A binary search is again performed to find the second edge.
Note that this scanning method sacrifices object detection size for speed. Similar to Single-Edge scan, Double-Edge scan
has some restrictions: the object should provide a solid obstruction; the size of the object will determine the maximum step
size.
Table 1: The Effect of Step Size on Minimum Object Detection Size
Step Size
Number of Beams
2 4 8 16 32
Minimum Object
Detection Size 5 mm (0.2 in) 10 mm (0.4 in) 20 mm (0.8 in) 40 mm (1.6 in) 80 mm (3.2 in)
Sensor response time is a function of sensor length and scanning method. Typical scan times are shown in the following
table.
Table 2: The Effect of Sensor Length and Scanning Method on Scan Time (Typical)
Maximum Scan Time (in milliseconds)
Array Length Straight Scan Single-Edge
Scan
Double-Edge Scan
Step 2 Beams Step 4 Beams Step 8 Beams Step 16 Beams Step 32 Beams
163 mm (6.4 in) 5.8 1.8 4.8 3.4 2.7 2.5 2.6
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