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.
A-GAGE®High-Resolution MINI-ARRAY®
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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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