EMX Industries ColorMax CM1000-1-4 User manual

C
Co ol lo or r s se en ns so or r
Operating Instructions

ColorMax Operating Instructions 2
Document No. 10030104
TABLE OF CONTENTS
1. CAUTION AND WARNING ............................................................................................3
2. PRODUCT OVERVIEW...................................................................................................3
3. PECIFICATION ........................................................................................................4
3.1. DI CRETE OUTPUT CHART FOR HEX MODEL ...................................................................5
3.2. RGB ANALOG OUTPUT ............................................................................................5
3.3. COLORMAX FLEX MODEL .......................................................................................... 5
4. QUICK TART............................................................................................................. 6
5. OFTWARE IN TALLATION ............................................................................................7
6. EN OR IN TALLATION ................................................................................................7
7. COLOR I/O ...............................................................................................................7
8. CONNECTION ...........................................................................................................8
9. COLORMAX APPLICATION PROGRAM............................................................................... 10
9.1. EN OR ETTING ................................................................................................. 10
9.1.1. AVERAGING ..................................................................................................... 10
9.1.2. TRIGGERING .................................................................................................... 10
9.1.3. MINIMUM OUTPUT DURATION (ms) ......................................................................... 11
9.1.4. ILLUMINATION (%) ............................................................................................. 11
9.1.5. READ COLORMAX ETTING .................................................................................. 11
9.1.6. END COLORMAX ETTING .................................................................................. 11
9.2. EN OR COMMUNICATION ...................................................................................... 11
9.2.1. PORT ............................................................................................................. 11
9.2.2. COMMUNICATION TATU .................................................................................... 12
9.2.3. ERIAL NO....................................................................................................... 12
9.3. COLOR RECOGNITION CHANNEL ............................................................................... 12
9.3.1. CHANNEL ........................................................................................................ 12
9.3.2. RECOGNITION MODE........................................................................................... 12
9.3.3. RECOGNITION ENABLED....................................................................................... 12
9.3.4. COLOR %......................................................................................................... 13
9.3.5. TOLERANCE % .................................................................................................. 13
9.3.6. MANUAL ......................................................................................................... 13
9.3.7. LUMINO ITY (%) ................................................................................................ 13
9.3.8. MATCH OUTPUT................................................................................................ 13
9.3.9. MULTI- AMPLE TEACH CHANNEL ............................................................................ 13
9.3.10. TEACH COLORMAX CHANNEL ................................................................................ 14
9.3.11. READ ALL COLORMAX CHANNEL ............................................................................ 14
9.3.12. END ALL COLORMAX CHANNEL ............................................................................ 14
9.4. CURRENT READING................................................................................................ 14
9.4.1. DI PLAY MODE.................................................................................................. 15
9.4.2. RECOGNIZED COLOR ......................................................................................... 15
10. PROGRAMMING COLOR RECOGNITION CHANNEL ............................................................... 15
11. EN OR DATA TRAN MI ION AND DATA LOGGING ............................................................. 16
11.1. U ING THE EXTERNAL TRIGGER TO TRAN MIT DATA .................................................... 16
11.2. U ING DATA LOGGING IN THE APPLICATION PROGRAM ................................................. 17
12. INPUT/OUTPUT IGNAL DE CRIPTION ........................................................................... 18
12.1. DI CRETE OUTPUT ........................................................................................... 18
12.2. ANALOG OUTPUT ............................................................................................. 18
12.3. EXTERNAL TRIGGER ........................................................................................... 18
13. APPLICATION NOTE ................................................................................................. 19
ColorMax POT IZE CHART .................................................................................................. 20
ORDERING INFORMATION ..................................................................................................... 20
ACCE ORIE .................................................................................................................... 21
CERTIFICATION : CE, C A, UL............................................................................................... 22
ColorMax CA E DIMEN IONAL OUTLINE ..................................................................................... 22

ColorMax Operating Instructions 3
Document No. 10030104
1. CAUTIONS AND WARNINGS
WARNING
1. The ColorMax is not intended for use in personal safety applications.
2. The ColorMax is not an explosion-proof enclosure. Do not use in an environment where flammable
materials are present.
3. The ColorMax sensor uses a high intensity, white LED, do not look directly into this light source.
IMPORTANT
This product is an accessory or part of a system. Always read and follow the manufacturer’s instructions for
the equipment before connecting this product. Comply with all applicable codes and safety regulations.
Failure to do so may result in damage, injury or death.
2. PRODUCT OVERVIEW
The ColorMax-1000 color sensors are designed to verify the presence of targets that can be differentiated by
color. The sensor projects a high intensity white light onto a target. The sensor analyzes the reflected light
for its constituent RGB (red, green, blue) values. If the readings of all of the three colors fall within the
preprogrammed parameters, the sensor issues a discrete signal that indicates a color match. A wide variety of
models provide color detection capabilities for the most demanding applications. High-speed discrete outputs
provide a standard interface to factory automation systems. Models include 3 spot sizes, up to 15 color
recognition channels and RGB analog outputs.
ColorMax Windows Application Program provides a comprehensive approach to sensor set-up, file
management and real-time sample analysis and evaluation.
Easy to use
The ColorMax Application Program provides a familiar Windows™ environment creating an intuitive user
interface. All essential sensor information is presented in one window including, sensor settings, color
recognition channel data and real-time display of color data. Features such as drop and check boxes
make selections and settings easy to change.
Flexibility
The ColorMax Application Program provides significant flexibility for set-up and operation. Features
such color/color & luminosity modes, color recognition tolerance settings for each color component
and separate NPN/PNP output selections are available for each color recognition channel.
Real-time display
Whenever the sensor is connected to the PC and the application program is running, the Current
Reading section shows the color components of the signal and the Recognized Colors status. In the
Color & Luminosity mode the bar graph provides a visual representation of each color component, red,
green and blue as a target is placed in the sensor’s viewing area. A numeric value is shown above the
bar graph indicating the percent of full scale for each color component. In the Color only mode a pie
chart indicates the proportion of each color component. This graphic display aids in set-up by showing
the signal levels for the users samples, allowing distance and sensor angle to be easily optimized for
reliable detection.
Windows  is a trademark of Microsoft Corporation
ColorMax  is a trademark of EMX Industries, Inc.

ColorMax Operating Instructions 4
Document No. 10030104
3. SPECIFICATIONS
ColorMax PECIFICATION
CM1000-1-4 CM1000-4-4 CM1000-7-4 CM1000-15 HEX4 CM1000-4-RGB4 CM1000-FLEX4 CM1000-1-8 CM1000-4-8 CM1000-7-8 CM1000-15 HEX8 CM1000-4-RGB8 CM1000-FLEX8 CM1000-7-25 CM1000-15 HEX25 CM1000-4-RGB25 CM1000-FLEX25
Light source White LED 400…700 nm
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Spot dia. @ 50 mm 4 mm
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8 mm
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25 mm
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Receiver RGB photodiode
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Sensing range 30 mm…100 mm
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Recommended sensing distance 50 mm
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Color recognition channels 1
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4
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7
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15
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Color recognition discrete outputs 1
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4
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7
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15 (4 binary coded discrete outputs)
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RGB analog outputs Red (0-5V), Green (0-5V), Blue (0-5V)
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Discrete outputs Programmable NPN/PNP
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Current (max.) 100 ma
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Voltage (max.) ensor V+
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Protection hort-circuit, transient, EMI
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Min. pulse duration (ms) 0, 10, 20…100
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Response time (ms) 0.330
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Switching frequency 20 kHz
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Indicator Red – channel match
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Green – power, no channel match
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Amber - teaching
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Controls PC Application program
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Communications R -232C/U B
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Data logging
PC Application program
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External trigger input ensor V+ (12…30 VDC @ 5 mA)
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Data transmission R -232C/U B
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Power 12…30 VDC @ 100 mA (max.)
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Protection Reverse polarity, over current (PTC fuse)
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Dimensions (length x dia.) 120 mm x 30 mm (1.5” x 1.25”)
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Weight 180 g (.4 lbs.)
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Housing material 316 stainless steel
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Type of protection IP67
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Operating temperature -10…55°C
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Storage temperature -20…70°C
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I/O connector Circular M12, 12 pin, IP67
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ColorMax Operating Instructions 5
Document No. 10030104
3.1. DISCRETE OUTPUT CHART FOR HEX MODELS
CM1000-15 HEX4, CM1000-15 HEX8, CM1000-15 HEX25
DISCRETE OUTPUTS
CHANNEL
MATCH C7 C6 C5 C4 C3 C2 C1
None not used not used not used gnd gnd gnd gnd
Channel 1 not used not used not used gnd gnd gnd +V
Channel 2 not used not used not used gnd gnd +V gnd
Channel 3 not used not used not used gnd gnd +V +V
Channel 4 not used not used not used gnd +V gnd gnd
Channel 5 not used not used not used gnd +V gnd +V
Channel 6 not used not used not used gnd +V +V gnd
Channel 7 not used not used not used gnd +V +V +V
Channel 8 not used not used not used +V gnd gnd gnd
Channel 9 not used not used not used +V gnd gnd +V
Channel 10 not used not used not used +V gnd +V gnd
Channel 11 not used not used not used +V gnd +V +V
Channel 12 not used not used not used +V +V gnd gnd
Channel 13 not used not used not used +V +V gnd +V
Channel 14 not used not used not used +V +V +V gnd
Channel 15 not used not used not used +V +V +V +V
3.2. RGB ANALOG OUTPUTS
CM1000-4-RGB4, CM1000-4-RGB8, CM1000-4-RGB25, CM1000-FLEX4, CM1000-
FLEX8 and CM1000-FLEX25
ColorMax provides an analog output signal for each color component (red, green, blue). The signal
resolution is 10-bit. The advantage of the analog outputs is that an external device can measure
these signals and a PC can analyze this data. There are data acquisition systems and PC cards
available to convert the analog signals to digital values in a PC or PLC environment. Once these
analog signals are converted to digital values further processing and analysis can be performed
allowing virtually unlimited number of colors to be recognized. The discrete output can only
indicate to the user that a sample is within or outside it’s tolerance range, the use of the analog
outputs allow continuous monitoring of a process allowing corrective action to be taken prior to
parts not meeting the pre-determined color selection criteria.
3.3. COLORMAX FLEX MODELS
CM1000-FLEX4, CM1000-FLEX8 and CM1000-FLEX25
The ColorMax FLEX models provide two methods collecting readings from the sensor, via the serial
port, to external devices.
First, the sensor can be set to transmit a reading, or series of readings, under control of the
External Trigger input line. The Application program is used to activate this feature. To utilize
this feature, the Edge or Level trigger mode is selected in the ensor ettings window (refer to
section 9.1.2 Triggering and section 11 ensor Data Transmission and Data Logging for further
information). Data may be acquired using a terminal program on a PC.

ColorMax Operating Instructions 6
Document No. 10030104
econd, a data-logging feature is provided in the Application program allowing readings to be saved
to a file for further analysis. et-up and control of the data logging is performed under control of
the Applications program (refer to section 9.1.2 Triggering and section 11 ensor Data Transmission
and Data Logging for further information).
4. QUICKSTART
This section provides step-by-step instruction on connection and set-up, allowing the user to become familiar
with operation of the sensor.
1. Determine which communications port on the PC will be used to communicate with the sensor. Install
the ColorMax Application software per instructions in the following section. When using the U B port
on the PC for communication, install the associated drivers during the Application installation.
2. Connect the sensor cable to the Color I/O per instructions in the CONNECTION section. Connect the
12V power supply as shown in the wiring diagram (observe polarity) and apply power.
3. The green LED on the sensor will indicate power is applied and the sensor is operational. Depending on
the sensor model number and discrete outputs available, various LEDs on the Color I/O will be
illuminated. For unconnected or unavailable channels, both LEDs on the Color I/O will be illuminated.
4. Connect either the R 232 or the U B cable from the Color I/O to the appropriate PC port. When using
the U B port, Windows© will detect the new hardware, and install the drivers. Upon completion
launch the Application program by double-clicking the program icon.
5. If the correct COM port is selected, the Application program will show the sensor model number and
serial number. If this information is not displayed, select a different COM port and press the reset
button. Once communication with the sensor is established the Application window will show the
sensor settings and current reading.
6. In the ensor ettings column select Averaging 64, Free Run, Minimum Output Duration 0 and press the
end ColorMax ettings button. In the Current Reading frame, select the Color and Luminosity display
mode.
7. elect several targets, solid color objects, paint samples, or other colored materials to evaluate. Place
the sensor at approximately 2” from the target, if the target is glossy, tilt the sensor on a slight 15 to
20˚ angle (from perpendicular to the target). When positioning targets in front of the sensor maintain
distance and angle by marking the surface in the test area.
8. tart with the lightest colored sample. Observe the RGB signals in the Current Reading section of the
display. Generally, the one or more of the red, green or blue signals should be in the 20% to 80% of full
scale range. If the signals are low, increase the illumination level. If any of the color signals are too
high, decrease the illumination level to bring the highest color signal between 80% to 90% of full scale.
To adjust the illumination level, move the slider to a new position and press the end ColorMax
ettings button.
9. After determining the appropriate illumination setting for the range of samples being evaluated a Color
Recognition Channel may be programmed. In the Color Recognition Channel frame, select Channel 1
from the drop box, check Color and Luminosity mode, check the Recognition Enabled box, set the
tolerances for each color to 20% using the Tolerance spin boxes. elect Match output High. After
making these selections, verify that the target is properly positioned in the sensor light spot. Press the
Teach ColorMax Channel button to program the selected channel to recognize the current target color.

ColorMax Operating Instructions 7
Document No. 10030104
Repeat this step by selecting the next Color Recognition channel, positioning the next target, then
teaching the channel.
10. After teaching several channels, note the status of the LEDs on the Color I/O box and the indicators in
the Recognized Colors frame in the Application program. Place target 1 into position in front of the
sensor. Observe the Channel 1 LED on the Color I/O box moves from the NPN to the PNP column
indicating recognition of the target color. Also note the indicator for Channel 1 in the Recognized
Colors frame is on. Remove target 1 and observe Channel 1 LED on the Color I/O box returns to the
NPN column and the Channel 1 indicator in the Recognized Colors frame is off. Repeat this process
with the other targets to see the sensor outputs change state as each is recognized by a different
channel.
11. When similar colors, or shades of the same color are used, it may be necessary to reduce the tolerance
settings to differentiate between them. Tolerance settings for a previously programmed channel can
be adjusted and resent to the sensor without reprogramming the channel by pressing the end All
ColorMax Channels button.
5. SOFTWARE INSTALLATION
Hardware requirements for ColorMax Application software installation and operation:
• CD ROM drive
• IBM compatible PC
• Windows 9XXX or higher
• R 232 serial interface port (COM1/COM2) or U B port
• VGA graphics or higher monitor
Insert the CD into the drive and follow the installation instructions on screen. Following installation of the
Application software, a prompt to install the U B drivers necessary to use U B interface will appear, continue
with the U B driver installation to use the U B port to communicate with the sensor. Upon successful
installation, double-click on the desktop icon to start the program.
6. SENSOR INSTALLATION
The ColorMax is provided with 2 jam nuts allowing it to be easily mounted thru a 30mm clearance hole. The
ColorMax bracket provides a 30mm clearance hole for the sensor and a pivot and slot for a #8 screw for
mounting the bracket. The slotted hole allows the angle of the sensor to target to be easily adjusted.
To achieve optimum performance it is recommended that samples be evaluated prior to permanent installation
of the sensor. During evaluation, sensor-to-target distance and sensor-to-target angle can easily be
determined by placing samples into the sensor’s field of view and observing the RGB color component signal
levels. When possible, it is generally best to set the sensor at a target distance that results in a signal level of
80% to 90% using the lightest sample. If necessary the illumination level may be reduced to prevent the sensor
from saturating on light colors.
7. COLOR I/O
The Color I/O board provides a means of connecting the sensor cable to other external devices. The I/O board
provides a set of LEDs for each channel that indicate the status of the discrete outputs for verification of
sensor operation and color recognition Connections are provided for both serial, R 232 and U B port. Either
may be used as a connection to a PC for set-up and programming of the ColorMax sensor. The drivers for the
U B port are installed during installation of the ColorMax Application oftware.

ColorMax Operating Instructions 8
Document No. 10030104
The R 232 connection consists of a modular jack (a phone style plug), cable and 9-pin adapter. To connect
the R 232 port, plug one end of the interface cable (with the RJ11 phone plugs) into the R 232 jack on the
Color I/O and the other end into the 9-pin adapter. Plug the adapter into the R 232 communications port on
the PC. Place the slide switch on the Color I/O to “R 232”.
The U B connection consists of a U B B jack on the Color I/O and a U B interface cable. To connect the U B
port, plug one end of the cable into the U B B jack on the Color I/O and the other end into the U B port on the
PC. Place the slide switch on the Color I/O to “U B”
In addition to a power indicator LED, there are 2 LEDs associated with each channel. The LEDs are arranged in
2 columns, one labeled PNP and the other labeled NPN. The PNP LED indicates that a channel output is high,
connected to sensor V+, while the NPN indicates that a channel output is low, connected to sensor ground.
Operation of the discrete channel outputs is dependent on whether the Match output is set to high or low for a
particular channel. Both PNP and NPN LEDs will be illuminated for channels that are not connected to the
Color I/O board such as models ColorMax-1000-1 and ColorMax-1000-4.
It is not necessary for the Color I/O board to be used; all sensor connections may be routed directly to the
appropriate devices such as a PLC.
8. CONNECTIONS
Sensor pin no. Wire color
CM1000-1-4 CM1000-1-8 CM1000-4-4 CM1000-4-8 CM1000-7-4 CM1000-7-8 CM1000-15 HEX4 CM1000-15 HEX8 Cm1000-15 HEX25
CM1000
-
4
-
RGB4
CM1000-4-RGB8 CM1000-4-RGB25 CM1000-FLEX4 CM1000-FLEX8 CM1000-FLEX25
1 Pink TX TX TX TX TX
2 Blue GND GND GND GND GND
3 Brown V+ V+ V+ V+ V+
4 Red ET ET ET ET ET
5 Green nc C4 C4 C4 C4
6 Black nc nc C5 nc RD
7 Yellow nc nc C6 nc GN
8 Gray nc nc C7 nc BL
9 White C1 C1 C1 C1 C1
10 Orange nc C3 C3 C3 C3
11 Purple RX RX RX RX RX
12 Lt. green nc C2 C2 C2 C2
Note: hield connection is not required, may be connected to earth ground

15 14 13 12 11 10
9 8 7 6 5 4 3 2 1 1
2 3 4 5 6 7 8 9
10 11 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
RS232
4 3 2 1 5 6
DB9F
1 2 3 4 5 6 7 8 9
USBB
1234
RS232
651 2 3 4
USBA 1
2 3 4
BOARD
COLORMAX I/O
BLACK YELLOW GRAY
CONNECTIONS FOR RGB OUTPUT MODELS
CHANNEL 7 CHANNEL 6 CHANNEL 5 CHANNEL 4 CHANNEL 3 CHANNEL 2 CHANNEL 1
GROUND
+V
RED 0-5V
GREEN 0-5V
BLUE 0-5V
EXT. TRIGGER
TRANSMIT
RECEIVE
PURPLE BROWN BLUE WHITE LT GREEN ORANGE GREEN RED PINK
SENSOR CONNECTIONS
CONNECTIONS FOR DISCRETE OUTPUT MODELS
GRAY YELLOW BLACK PINK RED GREEN ORANGE LT GREEN WHITE BLUE BROWN PURPLE RECEIVE
TRANSMIT
EXT. TRIGGER
BLUE 0-5V
GREEN 0-5V
RED 0-5V
+V
GROUND
CHANNEL 1 CHANNEL 2 CHANNEL 3 CHANNEL 4 CHANNEL 5 CHANNEL 6 CHANNEL 7
+V
GROUND
CHANNEL 1 CHANNEL 2 CHANNEL 3 CHANNEL 4 CHANNEL 5 CHANNEL 6 CHANNEL 7
RED 0-5V
GREEN 0-5V
BLUE 0-5V
EXT. TRIGGER
TRANSMIT
RECEIVE
USER I/O CONNECTIONS
NOTE: DO NOT CONNECT RS232 ON TB1
AND MODULAR JACK AT THE SAME TIME
COLOR RECOGNITION OUTPUTS
10 TO 30VDC POWER @ 100MA TYP.
ANALOG OUTPUT CHANNELS +V TO TRIGGER, OPEN IF NOT USED RS232 (SEE NOTE)
RED
YELLOW
BLACK
MODULAR JACK
TO 9-PIN FEMALE
SIGNAL GROUND
RECEIVE
TRANSMIT
SERIAL PORT
PC
01-18-06
MODULAR JACK
PC USB PORT
COMMUNICATIONS
SELECTOR
VBUS D- D+ GROUND
NOTE: On RGB models the black, yellow and gray wires
connect to the I/O terminals 10,11 and 12 respectively. On Sensor Connections Side
ColorMax Operating Instructions 9
Document No. 10030104
NOTE: On RGB models the black, yellow and gray wires connect
to the I/O bo terminals 10, 11 and 12 respectively.

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9. COLORMAX APPLICATION PROGRAM
ColorMax Application Program provides a comprehensive approach to sensor set-up, file management and real-
time sample analysis. The ColorMax Application Program provides a familiar Windows environment creating
an intuitive user interface. All essential sensor information is presented in one window including, sensor
settings, color recognition channel data and real-time display of color data. Features such as drop and check
boxes make selections and settings easy to change. After completing the installation procedure, double click
the ColorMax icon to open the application. During initialization, the application software interrogates the
ColorMax sensor to determine the serial number of the sensor and the specific sensor model. After reading the
sensor model number, the application will reconfigure to the appropriate model by changing the number of
channels indicated in the Recognized Colors section. Also, the general sensor settings and programmed colors,
if any, are read.
Once a sensor is set-up and programmed to recognize various colors the sensor operates as a stand-alone
device. It is not necessary to maintain a connection to the PC for normal operation.
The display window is segmented into four frames, ensor ettings, ensor Communications, Color Recognition
Channels and Current Reading. Each will be described in detail in the following sections.
9.1. SENSOR SETTINGS
ensor settings are parameters that apply to operation of the sensor. When a sensor is connected to the PC
the application program reads these parameters and updates the display. When changes are made to these
settings, the new settings must be downloaded to the sensor by selecting the end ColorMax ettings
button.
9.1.1. AVERAGING
Selections: 1,2, ,8,16,32,6
Default = 1
The Averaging drop box allows the user to select the number of measurements that are averaged to
obtain a reading that is checked for a match to programmed channels. The higher the number of
measurements that are averaged, the lower the variation in the reading allowing detection of subtle
differences in color. The lower the number of measurements that are averaged, the faster a match
can be detected. Ideally, the more averaging that can be accommodated within the speed constraints
of the application, the more accurate and reliable the detection of recognized colors.
9.1.2. TRIGGERING
Selections: Free Run, Level, Edge
Default = Free Run
The triggering options include Free Run, Level and Edge. In general applications, Free Run is the most
common. In Free Run mode, the sensor is measuring continuously, updating the discrete outputs
whenever the target meets a programmed color criteria.
Level and Edge triggering require the use of the External Trigger input on the sensor I/O connector.
Applying a voltage, 12-30VDC, not exceeding the sensor supply voltage, holds the input inactive.
Opening this connection will activate the External Trigger input. When Level is selected, and the
External Trigger input is active (no voltage applied), the sensor will continuously check for a color
match and update the discrete outputs until the Trigger input is deactivated (voltage is applied). The
discrete outputs will remain in the state that they are in when the Trigger input is deactivated. When
Edge is selected, the sensors will check for a color match on the each falling edge of the External
Trigger input and update the discrete outputs. The discrete outputs will remain in the state that they
are in when the Trigger input is deactivated. The External Trigger input is generally used when a

ColorMax Operating Instructions 11
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separate proximity sensor detects the presence of a sample and signals the sensor to check with the
pre-programmed color recognition channels to determine whether there is a match. Alternatively, the
sensor can be operated in the Free Run mode, and a separate proximity sensor can be connected to the
data acquisition system or PLC indicating a sample is present and the discrete output is valid.
9.1.3. MINIMUM OUTPUT DURATION (ms)
Selections: 0, 10, 20, 30, 0, 50, 60, 70, 80, 90, 100
Default = 0
The minimum output duration setting allows the user to increase the time that the discrete output(s)
indicate a match. When “0” delay is selected and a color match occurs, the appropriate channel’s
discrete output becomes active (i.e. changes state) as long as the match criteria is met. When a target
is moving at high-speed, presence of the target may be too short for the polling cycle of the data
acquisition system or PLC. In this case, increasing the minimum output duration lengthens discrete
output signal, allowing it to remain active long enough for the acquisition system to read its input port.
9.1.4. ILLUMINATION (%)
Adjustment range = 0 – 100%
The ColorMax allows the user to optimize the sensitivity of the sensor by adjusting the illumination
level to prevent the sensor from saturating. The illumination setting must be adjusted prior to
teaching the color recognition channels. Changing this setting after teaching will affect channels
selected for Color & Luminosity mode.
9.1.5. READ COLORMAX SETTINGS
The Read ColorMax ettings button causes the application program to read the current settings from
the sensor and display them in the ensor ettings section.
9.1.6. SEND COLORMAX SETTINGS
The end ColorMax settings button causes the application program to send the selected settings to the
sensor. When changes are made to the ensor ettings section the end ColorMax ettings button
must be selected to transmit the settings to the sensor.
9.2. SENSOR COMMUNICATIONS
The ensor Communications section provides user control of PC COM port selection and displays specific
sensor information.
9.2.1. PORT
The user may select the appropriate PC COM port for sensor R 232 or U B communications.
Color Sensor I/O with USB Interface Determining Windows™ COM port assignment
After installing Color ensor Application oftware and U B drivers connect the Color I/O interface
board to the PC using the U B cable. Windows will complete the driver installation.
Verify that the R 232/U B switch on the Color I/O interface board is in the U B position. Connect the
Color ensor to the Color I/O and apply power to the system.
In order for communications between the sensor and the PC to be established, it is necessary that the
appropriate COM port be selected in the Port drop box.
1. Launch the Application program. Observe the Communications tatus box in the lower left
corner of the Application window. If the message “Waiting for…..” is displayed, then an
incorrect COM port is selected. Close the Application program.

ColorMax Operating Instructions 12
Document No. 10030104
2. To determine the COM port assignment select the Windows™ Control Panel, ystem Properties.
elect the Hardware tab and the Device Manager. croll down the device list to Ports (COM &
LPT) and expand the list (+). The Color ensor port assignment will be shown in the list.
3. Close the Control Panel windows and launch the Application program. elect the appropriate
COM port in the drop box and select the Reset button. Communications with the sensor are
now established.
9.2.2. COMMUNICATION STATUS
The Communications status box shows the ColorMax model and the connection status, either on line
indicating normal communication or Communication lost indicating a disruption in communications.
After initiating a Teach command, while the sensor is executing the instruction, the status box
indicates Teaching Channel X…
9.2.3. SERIAL NO.
The erial Number box shows the serial number of the sensor currently connected.
9.3. COLOR RECOGNITION CHANNELS
The Color Recognition Channels section of the display window contains all color matching channel
parameters. The number of color recognition channels is dependent on the ColorMax model and the
application program configures for the appropriate model. All of the selections in this section are channel
specific. For example, one channel can be programmed to output a high level when a match occurs while
another channel can be programmed to output a low level when a match occurs. With the exception of the
ColorMax-1000-15HEX models, Color Recognition Channels can be programmed to achieve multiple match
outputs. For example, channel 1 can be programmed to 5% tolerance, channel 2 to 10% tolerance and
channel 3 to 15% tolerance using the same sample. This allows the user to monitor variations in samples
for further process analysis. The ColorMax-1000-15HEX models provide four discrete signals in a binary
format and as such, only one output may be active at a time.
9.3.1. CHANNEL
The channel drop box shows the number of channels available for color recognition. elect the
appropriate channel prior to changing the associated parameters. Note that the number of color
recognition channels is dependent on the ColorMax model.
9.3.2. RECOGNITION MODE
There are two color recognition modes; Color & Luminosity and Color only. The Color only mode
compares the proportion of each color component in the signal, checking to determine that the
proportions are within the allowable tolerance to detect a match. This allows for greater variation in
sensor-to-target distance than the Color & Luminosity mode. The Color & Luminosity mode evaluates
each color component, the luminosity level of each and compares them to the programmed values
within the allowable tolerance. The ColorMax allows users to select color and color & luminosity
modes on an individual channel basis. Color and luminosity provides the highest precision while Color
only is better suited in applications where target flutter is present.
9.3.3. RECOGNITION ENABLED
The Recognition Enabled check box allows the user to enable or disable a particular channel without
altering the programmed color recognition settings. A single channel or multiple channels can be
temporarily disabled causing the sensor suspend checking of that channel for a color match. To
disable a channel, uncheck the Recognition Enabled box and select the end All ColorMax channels
button.

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Document No. 10030104
9.3.4. COLOR %
The RED, GREEN and BLUE Color (%) boxes show the values programmed into the selected channel. If
the channel was programmed in the Color & Luminosity mode, these values represent a percent of full
scale for each color component. If the channel was programmed in the Color only mode, these values
represent the proportion of each color component in the composite signal (i.e. the sum of the color
components = 100%).
9.3.5. TOLERANCE %
The Tolerance spin boxes are used to set the tolerance for each color component individually. When
the colors of the samples are significantly different, for example, red, brown, yellow, then the
tolerance setting may be set to a higher value. When the colors of the samples are very similar, for
example similar intensities of the same hue (i.e. color), then tighter tolerance settings are necessary
for reliable differentiation. For applications that require tight tolerance settings (<2%), allow the
sensor to warm-up for 30 minutes prior to use.
9.3.6. MANUAL
The Manual button opens a Manual Entry window that allows previously determined Color (%) and
Tolerance (%) values to be entered by the user. This function is only available when the Recognition
Mode for the selected channel is set to Color and Luminosity.
After entering the desired values, select the OK button to store the values or cancel to exit without
changes.
9.3.7. LUMINOSITY (%)
The Luminosity box shows the average of the red, green and blue color % for the selected channel
when in the Color & Luminosity Recognition Mode. When Color only is selected the Luminosity box is
blank.
9.3.8. MATCH OUTPUT
The Match output setting allows the operator to select either High or Low output on the associated
discrete output when a match occurs. By selecting High the output will pull to sensor V+ and by
selecting Low the output will pull to sensor ground. Whenever a channel is in a non-match condition
the output will pull to the opposite state.
9.3.9. MULTI-SAMPLE TEACH CHANNEL
The Multi- ample Teach Channel button opens a window that allows multiple samples or multiple
points on a sample to be measured. These measurements are analyzed and the appropriate settings
that allow a match for all of the samples are calculated and are shown in the Result frame. Up to 10
measurements may be made. elect the OK button to store the values or cancel to exit without
changes.

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Document No. 10030104
9.3.10. TEACH COLORMAX CHANNEL
The Teach ColorMax Channel button initiates a sequence of sampling the input signals resulting in
current values, tolerances and other specific channel parameters to be stored in the sensor. Executing
the teach function applies only to the selected channel. While the teach function is performed by the
sensor for several seconds all user selections in the application program are temporarily disabled.
9.3.11. READ ALL COLORMAX CHANNELS
The Read All ColorMax Channels button allows the application to load previously programmed settings
from a sensor into the application program for review, modification or saving to a file. Reading the
channels from the sensor into the application will overwrite any current settings and parameters in the
Color Recognition section of the display window.
9.3.12. SEND ALL COLORMAX CHANNELS
The end All ColorMax Channels button sends all the settings and parameters for all channels to the
sensor. This function is useful when recalling a saved file to re-programming the sensor.
9.4. CURRENT READING
The Current Reading section of the display shows current information received from the sensor. This
allows the user to place samples in the viewing area of the sensor and observe the levels of the red, green

ColorMax Operating Instructions 15
Document No. 10030104
and blue components. The Current Reading display is useful in initial set-up for determining optimum
sensor-to-target distance, sensor-target angle and relative reflected intensity of multiple samples prior to
beginning the teaching sequence.
9.4.1. DISPLAY MODE
The Display Mode allows the user to select Color & Luminosity, resulting in a bar graph display of
current reading, or Color only, resulting in a pie chart representation of current reading.
• Color and luminosity
The Color & Luminosity selection shows a bar graph of the red, green and blue components.
The numeric value in the display boxes above the bar graph show the percent of full scale for
each color component. Indicators on the chart show 20% and 80% of full scale.
• Color only
The Color only selection shows a pie chart of the red, green and blue components representing
the proportion of each color component in the reflected signal. The numeric value in the
display boxes above the bar graph show the proportion of each color component in the current
reading.
9.4.2. RECOGNIZED COLORS
The Recognized Colors section shows the current status of the programmed color recognition channels
and coincides with the current state of the discrete outputs. The number of color recognition channels
is dependent on the ColorMax model. This section will automatically configure to display the
appropriate number of channels. When a channel match occurs, the indicator will change to blue and
the output state box will indicate either high or low as specified by the Match output selection for that
channel. The ColorMax-1000-15HEX models provide four discrete signals in a binary format and as
such, only one color recognition channel output may be active at a time.
10. PROGRAMMING COLOR RECOGNITION CHANNELS
To program ColorMax sensor to recognize user samples double-click on the ColorMax icon to open the
Windows™ Application Program. The following description illustrates a typical set-up of the Color Recognition
Channels. ome of the settings suggested may be adjusted based on the specific requirements of a particular
application.
1. Acquire samples of all colors that will be programmed into the color recognition channels.
For optimum operation select a target distance that is best suited for the range of colors
being detected. When using shiny/glossy targets, set the sensor on a 20° to 25° angle to
prevent direct reflection.
2. et sensor averaging to a lower value, 1,2, 4 or 8 for higher speed applications or 16, 32 or
64 for higher precision applications.
3. elect the appropriate mode; free run, level or edge triggered depending on the
application requirements.
4. et the illumination level to 100%.
5. Press the end ColorMax ettings button to send the settings to the sensor.
6. To determine which sample provides the highest signal level, place the sample that
appears to be the lightest in the sensor field of view.

ColorMax Operating Instructions 16
Document No. 10030104
7. Observe the signal level for each color component. Generally, best results are achieved by
setting the sensor-to-target distance to obtain a signal level near 80% as indicated in the
Current Reading frame in the Application window. Check the remaining samples to verify
that the signal levels for each of the color components are below the full scale, 100%,
level.
8. If the required sensor-to-target distance is such that the lightest sample, with the highest
signal level, saturates one or more color channels, it is necessary to reduce the
illumination setting. In the ensor ettings frame, lower the illumination and press the
end ColorMax ettings button. Repeat this adjustment until the color levels are near 80%
as indicated in the Current Reading frame. Note that any change in the illumination
setting after teaching of one or more Color Recognition Channels may require re-teaching
of these channels for reliable operation.
9. Once the sensor–to-target distance and illumination level have been established the Color
Recognition channels may be programmed.
• elect a channel in the Channel pull-down list.
• elect the Recognition Mode, Color & Luminosity or Color Only.
• elect the Recognition Enabled check box.
• et the tolerance levels for each color component in text box below each color value.
Generally, a tolerance of 5% to 10% is suitable for color recognition when the target
colors are visually different. In cases where the colors are very similar, it may be
necessary to use lower tolerance settings.
• elect the Match output to be high or low.
10. Place the target in the sensor field of view and press the Teach ColorMax Channel button.
The sensor will determine the RGB for the samples and store them for the selected
channel.
11. Repeat this process with each of the samples, selecting a different Color Recognition
Channel for each. Once all of the samples have been programmed into a channel, place
each sample, one at a time in the sensors field of view and verify that the correct channel
indicates a match while the other channels do not indicate a match.
11. SENSOR DATA TRANSMISSION AND DATA LOGGING
This section applies to ColorMax FLEX models only
The ColorMax FLEX models provide two methods collecting readings from the sensor, via the serial port, to
external devices.
11.1. USING THE EXTERNAL TRIGGER TO TRANSMIT DATA
First, the sensor can be set to transmit a reading, or series of readings, under control of the External
Trigger input line. The Application program is used to activate this feature. To utilize this feature, the
Edge or Level trigger mode is selected in the ensor ettings window (refer to section 9.1.2 Triggering for
further information). When the external triggering function is used on a ColorMax FLEX model, the sensor
will transmit a set of readings via the serial port when the External Trigger input is active (refer to section
12.1.3 External Triggering for description of hardware operation). If the sensor is set for edge trigger, one
set of readings will be transmitted with each high to low transition of the External Trigger input. If the
sensor is set for level trigger, readings will be transmitted continuously while the External Trigger input
line is low.

ColorMax Operating Instructions 17
Document No. 10030104
NOTE When using the Application program, always disable the external triggering by placing it high
(V+).
A CII data may be acquired using a terminal program on a PC. The COM port settings are 9600 BAUD, 7
data bits, even parity, 1 stop bit, and flow control is set to none. The maximum data rate is approximately
40 measurements per second.
DATA FORMAT: !d,aaaa,bbbb,cccc,d
!d = command acknowledgement
a = Red reading, % full-scale (Hexadecimal value)
b = Green reading, % full-scale (Hexadecimal value)
c = Blue reading, % full-scale (Hexadecimal value)
d = recognized color(s) (0-based bitmapped)
EXAMPLE:
!d,9FB5,8F41,90EF,05
CONVER ION OF HEXADECIMAL VALUE TO % FULL CALE VALUE
Hexadecimal 9FB5 8F41 90EF
Decimal 40885 36673 37103
% full scale 40.885 36.673 37.103
RECOGNIZED COLOR( )
A CII Characters DB7 DB6 DB5 DB4 DB3 DB2 DB1 DB0
00 0 0 0 0 0 0 0 0
05 0 0 0 0 0 1 0 1
23 0 0 1 0 0 0 1 1
NOTE: 1 indicates recognized color
0 indicated unrecognized color
11.2. USING DATA LOGGING IN THE APPLICATION PROGRAM
econd, a data-logging feature is provided allowing readings to be saved to a C V (comma-separated-
variable) file for further analysis. Each set of readings is time/date stamped. et-up and control of the
data logging is performed under control of the Applications program. Communications with the sensor via
the Application program occurs 3 – 4 times per second.
Data log format: 9:10:58,39.6,36.7,37.7, 1
Time stamp, red % full-scale, green % full-scale, blue % full-scale, recognized color
recognized color(s) (0-based bitmapped) (refer to table in section 11.1)
1. elect the OPTION menu item and then select DATA LOGGING, ETTING .
2. elect one of the following modes:
CONTINUOUS LOGGING
Logs data to the file continuously at a rate of 3 – 4 readings per second.
LOG ON MATCH
Logs data to the file when a channel match occurs. One or more channels may match.
LOG ON INTERVAL
Logs data to the file at the specified interval.
3. elect the filename and file location.

ColorMax Operating Instructions 18
Document No. 10030104
4. elect OPTION , DATA LOGGING, TART to begin logging data to a file. A message at the bottom of
the Application screen indicates logging is in process.
5. elect OPTION , DATA LOGGING, TOP to terminate logging.
The log file may be opened in a text editor or spreadsheet for further analysis. A sample log file is
shown below:
9:10:58 39.6 36.7 37.7 1
9:11:21 37.4 34.6 35.1 1
9:11:25 39.6 36.6 37.5 1
9:11:29 39.5 36.6 37.6 1
9:11:30 39.4 36.5 37.5 1
9:11:33 39.8 36.8 37.9 1
12. INPUT/OUTPUT SIGNAL DESCRIPTIONS
12.1. DISCRETE OUTPUTS
The discrete output(s) are a PNP/NPN configuration allowing the user to provide a load on this output that
is either pulled high to sensor V+ or low to ground. This output is typically connected to a PLC. The output
remains active as long as the target meets the criteria for a color match. In high-speed applications it may
be useful to use the Minimum Output Duration feature to lengthen the signal duration to meet acquisition
requirements of the PLC.
12.2. ANALOG OUTPUTS
ColorMax provides an analog output signal for each color component (red, blue, green). The analog
outputs are 0-5V with 5mV resolution (10-bit). Any standard analog input channels typically available on a
PLC may monitor these outputs. The analog output signals are useful in applications where simply
detecting a color match insufficient. For example, constant real-time monitoring of individual red, green
and blue color components in process allows minor fluctuations or trends to be detected permitting
corrective action to be taken prior to parts not meeting the color criteria.
12.3. EXTERNAL TRIGGER
The triggering options include Free Run, Level and Edge. Level and Edge triggering require the use of the
External Trigger input on the sensor I/O connector. Applying sensor supply voltage, 12-30VDC, not
exceeding the sensor supply voltage, de-activates the External Trigger input. When Level is selected, and
the External Trigger input is active (open-0V), the sensor will continuously check for a color match and
update the discrete outputs until the Trigger input is deactivated(returns to sensor supply voltage). The
discrete outputs will remain in the state that they are in when the Trigger input is deactivated. When Edge
is selected, the sensor will check for a color match on the each falling edge of the External Trigger input
and update the discrete outputs. The discrete outputs will remain in the state that they are in when the
Trigger input is deactivated and remain in that state until the next trigger event.
The External Trigger input is generally used when a separate proximity sensor detects the presence of a
sample and signals the sensor to check with the pre-programmed color recognition channels to determine
whether there is a match. Alternatively, the sensor can be operated in the Free Run mode, and a separate
proximity sensor can be connected to the data acquisition system or PLC indicating a sample is present and
the sensor’s discrete output is valid.
ColorMax CM1000-FLEX models provide a feature that allows the External Trigger input to initiate the
transmission of a reading or series of readings via the sensor’s serial interface (refer to section 9.1.2
Triggering and section 11 ensor Data Transmission and Data Logging for further information).

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13. APPLICATION NOTES
SENSOR RANGE
Range is dependent on target color(s). Darker colors absorb more light and consequently return less signal than
lighter colors, therefore, may require shorter sensor-to-target distance.
SPOT SIZE
In most applications, the target color should be contained within the illuminated area. For example, a target
that is only partially in the illuminated area will cause the sensor to include color signal from the surrounding
area, which may affect the ability to reliably recognize the target color. The spot size is generally dependant
on the application. The advantage of a larger spot is that the measurement is averaged over a larger area,
allowing the sensor to ignore slight variations. For example, a textured surface such as carpet or a multi-
colored object that does not have a uniform color should be viewed over a larger area to minimize variations in
readings. A smaller spot size is necessary in applications where the target is relatively small, such as a
registration mark, a pill or other small object. Best results are achieved when the target color is completely
within the illuminated area.
GLOSSY SAMPLES
When sensing color variations on shiny, glossy, highly reflective surfaces, it is recommended that that the
sensor be positioned at a 15-20° from perpendicular to the sample surface. This is helpful in avoiding direct
reflection of the sensor light source back into the sensor lens.
TOLERANCE SETTINGS
When signal levels are low (ex. Dark colors), low tolerance settings in the range of .5 to 5% will result in very
high detection sensitivity. mall variation in color may result in a sample not meeting the color recognition
criteria. Generally, at low signal levels, relaxing the tolerance results in more reliable operation. For
applications that require tight tolerance settings (<2%), allow the sensor to warm-up for 30 minutes prior to
use.

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ColorMax SPOT SIZE CHART
ColorMax spot size
0
10
20
30
40
50
60
0 20 40 60 80 100 120
Sensor-to-target distance (mm)
Spot size (mm)
4mm
8mm
25mm
ORDERING INFORMATION
CM1000-1-4 Color sensor, one discrete output, 4mm spot
CM1000-4-4 Color sensor, four discrete outputs, 4mm spot
CM1000-7-4 Color sensor, seven discrete outputs, 4mm spot
CM1000-15HEX4 Color sensor, fifteen encoded discrete outputs, 4mm spot
CM1000-4-RGB4 Color sensor, four discrete outputs, RGB outputs, 4mm spot
CM1000-FLEX4 Color sensor, four discrete outputs, RGB outputs, data transmission, 4mm spot
CM1000-1-8 Color sensor, one discrete output, 8mm spot
CM1000-4-8 Color sensor, four discrete outputs, 8mm spot
CM1000-7-8 Color sensor, seven discrete outputs, 8mm spot
CM1000-15HEX8 Color sensor, fifteen encoded discrete outputs, 8mm spot
CM1000-4-RGB8 Color sensor, four discrete outputs, RGB outputs, 8mm spot
CM1000-FLEX8 Color sensor, four discrete outputs, RGB outputs, data transmission, 8mm spot
CM1000-7-25 Color sensor, seven discrete outputs, 25mm spot
CM1000-15HEX25 Color sensor, fifteen encoded discrete outputs, 25mm spot
CM1000-4-RGB25 Color sensor, four discrete outputs, RGB outputs, 25mm spot
CM1000-FLEX25 Color sensor, four discrete outputs, RGB outputs, data transmission, 25mm spot