DF-G2-PC-Q3

DF-G2 High Speed Expert™ Dual Display Small Object Counter Quick Start Guide Advanced sensor with dual digital displays for small object counting applications For complete technical information about this product, including dimensions, accessories, and specifications, go to www.bannerengineering.com and search for your model number. 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 deenergized (off) output condition. Overview Figure 1. DF-G2 Model Features 1 Output LED 2 LO/DO Switch 3 RUN/PRG/ADJ Mode Switch 4 Lever Action Fiber Clamp 5 Red Signal Level 6 Green Threshold 7 +/SET/- Rocker Button Models Connector 1 Model Outputs DF-G2-NC-2M Single NPN, plus Health Mode output DF-G2-PC-2M Single PNP, plus Health Mode output DF-G2-NC-Q5 Single NPN, plus Health Mode output DF-G2-PC-Q5 Single PNP, plus Health Mode output DF-G2-NC-Q7 Single NPN, plus Health Mode output DF-G2-PC-Q7 Single PNP, plus Health Mode output 2 m (6.5 ft) cable, 5-wire 150 mm (6 in) PVC cable with a 5-pin M12 quick disconnect Integral 5-pin M8 quick disconnect Fiber Optic Arrays Models 2 PFCVA-10X25-S PFCVA-10X25-E PFCVA-25X25-S PFCVA-25X25-E Detection Window Dimensions Fiber Exit Side exit 10 mm x 25 mm End exit Side exit 25 mm x 25 mm End exit Minimum Object Size 3 1.5 mm 3 mm 1 Connector options: • A model with a QD connector requires a mating cordset • For 9 m cable, change the suffix 2M to 9M in the 2 m model number (example, DF-G2-NC-9M) • For 150 mm (6 in) PVC cable with a 5-pin M8 QD model, change the suffix 2M to Q3 in the 2 m model number (example, DF-G2NC-Q3) • For Q3 and Q7 models, use a 5-pin M8 or a 6-pin M8 mating cordset 2 Custom fiber arrays and mounting configurations are possible. Consult factory for assistance with your small object counting application. 3 With 2% threshold offset percentage Original Document 178061 Rev. F 9 September 2021 178061 DF-G2 High Speed Expert™ Dual Display Small Object Counter Fiber Optic Arrays Models 2 Detection Window Dimensions PFCVA-34X25-S PFCVA-34X25-E 34 mm x 25 mm Fiber Exit Side exit End exit Minimum Object Size 3 4 mm Installation Instructions Mounting Instructions Mount on a DIN Rail 1. Hook the DIN rail clip on the bottom of the DF-G2 over the edge of the DIN rail (1). 2. Push the DF-G2 up on the DIN rail (1). 3. Pivot the DF-G2 onto the DIN rail, pressing until it snaps into place (2). Mount to the Accessory Bracket (SA-DIN-BRACKET) 1. Position the DF-G2 in the SA-DIN-BRACKET. 2. Insert the supplied M3 screws. 3. Tighten the screws. Remove from a DIN rail 1. Push the DF-G2 up on the DIN rail (1). 2. Pivot the DF-G2 away from the DIN rail and remove it (2). Installing the Fibers in a DF-Gx Sensor Follow these steps to install glass or plastic fibers. 1. 2. 3. 4. 5. Open the dust cover. Move the fiber clamp forward to unlock it. Insert the fiber(s) into the fiber port(s) until they stop. Move the fiber clamp backward to lock the fiber(s). Close the dust cover. Move forward to release the fibers Fiber Clamp Fiber Receiver Port Fiber Emitter Port 2 Custom fiber arrays and mounting configurations are possible. Consult factory for assistance with your small object counting application. 3 With 2% threshold offset percentage 2 www.bannerengineering.com - Tel: + 1 888 373 6767 P/N 178061 Rev. F DF-G2 High Speed Expert™ Dual Display Small Object Counter Fiber Adapters Note: If a thin fiber with less than 2.2 mm outer diameter is used, install the fiber adapter provided with the fiber assembly to ensure a reliable fit in the fiber holder. Align the fibers to the end of the adaptors. Banner includes the adapters with all fiber assemblies. TO FIBERS TO SENSOR Fiber Outer Diameter (mm) Adapter Color Ø 1.0 Black Ø 1.3 Red Ø 2.2 No adapter needed When connecting coaxial-type fiber assemblies to the amplifier, install the single-core (center) fiber to the Transmitter port, and the multi-core (outer) fiber to the Receiver port. This will result in the most reliable detection. RECEIVER Multi-core fiber Single-core fiber TRANSMITTER Wiring Diagrams PNP Models 1 + 10–30 V dc – 3 4 2 5 NPN Models 3 4 Load 2 Health Remote Programming (N.O.) – 10-30V dc + 1 5 Load Key 1 = Brown 2 = White 3 = Blue 4 = Black 5 = Gray (6 = no connection) Health Remote Programming (N.O.) Note: Open lead wires must be connected to a terminal block. Top Panel Interface Opening the dust cover provides access to the top panel interface. The top panel interface consists of the RUN/PRG/ADJ mode switch, LO/DO switch, +/SET/- rocker button, dual red/green digital displays, and output LED. P/N 178061 Rev. F www.bannerengineering.com - Tel: + 1 888 373 6767 3 DF-G2 High Speed Expert™ Dual Display Small Object Counter RUN/PRG/ADJ Mode Switch The RUN/PRG/ADJ mode switch puts the sensor in RUN, PRG (Program), or ADJ (Adjust) mode. RUN mode allows the sensor to operate normally and prevents unintentional programming changes via the +/SET/- button. PRG mode allows the sensor to be programmed through the display driven programming menu (see Program Mode below). ADJ mode allows the user to perform Expert TEACH/SET methods and Manual Adjust (see Adjust Mode below). LO/DO Switch The LO/DO switch is used to select Light Operate or Dark Operate mode. In Light Operate mode, the output is ON when the sensing condition is above the threshold (for Window SET, the output is ON when the sensing condition is inside the window). In Dark Operate mode, the output is ON when the sensing condition is below the threshold (for Window SET, the output is ON when the sensing condition is outside the window). +/SET/- Rocker Button The +/SET/- rocker button is a 3-way button. The +/- positions are engaged by rocking the button left/right. The SET position is engaged by clicking down the button while the rocker is in the middle position. All three button positions are used during PRG mode to navigate the display driven programming menu. During ADJ mode, SET is used to perform TEACH/SET methods. The rocker button is disabled during RUN mode, except when using Window SET, see Window SET on p. 6. Red/Green Digital Displays During RUN and ADJ mode, the Red display shows the signal level and the Green display shows the threshold or the total counts. During PRG mode, both displays are used to navigate the display driven programming menu. Output LED The output LED provides a visible indication when the output is activated. Operating Instructions Remote Input For more information about how to perform TEACH/SET methods and to program the sensor remotely, see www.bannerengineering.com and search 178236. Run Mode Run mode allows the sensor to operate normally and prevents unintentional programming changes. The +/SET/- rocker button is disabled during RUN mode, except when using Window SET. In RUN Mode, the SET function of the +/SET/- rocker button allows the user to toggle between the threshold center value and the total number of counts on the Green display. If the Totalizer function is enabled, the total counts value increments to the programmed value and then starts over at 0. If the Totalizer function is disabled, the total counts value increments to 9999 and then starts over at 0. Changing any operational setting causes the total counts value to reset to 0. 4 www.bannerengineering.com - Tel: + 1 888 373 6767 P/N 178061 Rev. F DF-G2 High Speed Expert™ Dual Display Small Object Counter Program Mode Figure 2. PROGRAM MODE Mode Switch to “PRG” SET - + To scroll through menu lists: Press “+” or “-” To enter a choice list or to select and save: Click SET To exit a choice list without saving: Press and hold SET for 2 seconds rocker button Menu List Click SET to enter choice list DISPLAY LOOP DISPLAY LOOP Press and hold SET to exit choice list without saving Click SET to enter choice list Click SET to enter choice list Click SET to enter choice list Click SET to enter choice list Click SET to enter choice list Click SET to enter choice list Click SET to enter choice list DISPLAY LOOP DISPLAY LOOP (+) or (-) to set value (+) or (-) to set value (+) or (-) to set value (+) or (-) to set value (display flips 180˚) Click SET to select and save a choice in any list Return to Menu List on display represents a “w” on display represents a “m” Program (PRG) mode allows the following settings to be programmed in the DF-G2 Factory Default Settings: Setting Factory Default Threshold 3700 (typical) TEACH Selection Window SET Response Speed Standard: 250 µs Offset Percent 2% Totalizer Counts OFF Totalizer One-Shot OFF Dynamic Event Stretcher 50% Display Readout Numeric, ECO disabled, Normal Orientation Adjust Mode Sliding the RUN/PRG/ADJ mode switch to the ADJ position allows the user to perform Expert TEACH/SET methods. TEACH Procedures The instruction manual has detailed instructions for these TEACH modes: P/N 178061 Rev. F www.bannerengineering.com - Tel: + 1 888 373 6767 5 DF-G2 High Speed Expert™ Dual Display Small Object Counter • • • Window SET Light SET Dynamic TEACH Window SET • • • • Sets window thresholds that extend a programmable % offset above and below the presented condition All other conditions (lighter or darker) cause the output to change state Recommended for applications where a product may not always appear in the same place, or when other signals may appear See Program Mode for programming the Offset Percent setting (to increase/decrease the window size) A single sensing condition is presented, and the sensor positions window thresholds a programmable % offset above and below the presented condition. In LO mode, Window SET designates a sensing window with the Output ON condition inside the window, and the Output OFF conditions outside the window. Figure 3. Window SET (Light Operate shown) Sensing Window Sensor positions window thresholds a programmable % offset from the presented condition Output OFF Output ON Darkest (no signal) Output OFF Condition Presented Most Light (saturated signal) Output ON and OFF conditions can be reversed using the LO/DO switch. Light SET • • • Sets a threshold a programmable % offset below the presented condition Changes output state on any condition darker than the threshold condition Recommended for applications where only one condition is known, for example a stable light background with varying darker targets • See Program Mode for programming the Offset Percent setting (to increase/decrease the window size) A single sensing condition is presented, and the sensor positions a threshold a programmable % offset below the presented condition. When a condition darker than the threshold is sensed, the output either turns ON or OFF, depending on the LO/DO setting. Figure 4. Light SET (Light Operate shown) Threshold Position Sensor positions threshold a programmable % offset below the presented condition Output OFF Darkest (no signal) Output ON Condition Presented Most Light (saturated signal) Dynamic TEACH • • Teaches on-the-fly Establishes a single switching threshold Dynamic TEACH is best used when a machine or process may not be stopped for teaching. The sensor learns during actual sensing conditions, taking multiple samples of the light and dark conditions and automatically setting the threshold at the optimum level. 6 www.bannerengineering.com - Tel: + 1 888 373 6767 P/N 178061 Rev. F DF-G2 High Speed Expert™ Dual Display Small Object Counter Figure 5. Dynamic TEACH (Light Operate shown) Darkest Taught Condition Lightest Taught Condition Sensor positions threshold midway between taught conditions Output OFF Darkest (no signal) Output ON Position Most Light (saturated signal) The output ON and OFF conditions can be reversed using the LO/DO switch. Troubleshooting Percent Minimum Difference after TEACH The Dynamic TEACH method will flash a % minimum difference on the displays after a PASS or FAIL. Value PASS/FAIL Description 0 to 99% FAIL The difference of the taught conditions does not meet the required minimum 100 to 300% PASS The difference of the taught conditions just meets/exceeds the required minimum, minor sensing variables may affect sensing reliability 300 to 600% PASS The difference of the taught conditions sufficiently exceeds the required minimum, minor sensing variables will not affect sensing reliability 600% + PASS The difference of the taught conditions greatly exceeds the required minimum, very stable operation Percent Offset after SET The Window and Light SET methods will flash a % offset on the displays after a PASS or FAIL. SET Result % Offset Meaning PASS (with % Offset) Displays the % offset used for the SET method FAIL (with % Offset) Displays the minimum required % offset necessary to PASS the SET method FAIL (without % Offset) Presented condition cannot be used for the SET method Health Mode Alarm The Health Mode Alarm alerts you when preventative maintenance becomes necessary to ensure reliable sensing. The Health Mode output 2 is Active when the system is OK and operating normally. Health Mode output 2 becomes Inactive when the system is in a marginal state because of contamination. The system still operates normally and can detect small objects, but is nearing the alarm state. When the system is completely contaminated and unable to ensure reliable sensing, the system goes into the alarm state. In the alarm state, the discrete output 1 is forced to the blocked state and can no longer be used to detect small objects. • displays when Health Mode output 2 is inactive because of contamination. The system Threshold Alert operates normally but is nearing the alarm state. • Threshold Error detect small objects. displays when discrete output 1 is forced to the blocked state and can no longer be used to The sensor may enter Health Mode Alarm for any of these reasons: 1. When first powered up; the fiber optic array may already be contaminated 2. If the Window SET procedure fails, indicating the fiber optic array is contaminated and the sensor could not set a valid clearstate light level for reliable detection 3. If the fiber optic array is contaminated enough that the auto compensation tracking algorithm cannot sufficiently adjust the thresholds to ensure reliable detection 4. If the fiber optic array is blocked for more than 2 seconds Return the system to normal operation by cleaning the fiber optic array and performing a Window SET to reset the clear-state light level (see Window SET on p. 6). P/N 178061 Rev. F www.bannerengineering.com - Tel: + 1 888 373 6767 7 DF-G2 High Speed Expert™ Dual Display Small Object Counter Specifications Sensing Beam Visible red, 635 nm Supply Voltage 10 V DC to 30 V DC Class 2 (10% maximum ripple) Power and Current Consumption (exclusive of load) Standard display mode: 960 mW, Current consumption < 40 mA at 24 V DC ECO display mode: 720 mW, Current consumption < 30 mA at 24 V DC Supply Protection Circuitry Protected against reverse polarity and transient overvoltages Delay at Power-Up 500 milliseconds maximum; outputs do not conduct during this time Output Configuration 1 NPN or 1 PNP output, depending on model, plus 1 Health Mode output Output Rating 100 mA maximum combined load (derate 1 mA per °C above 30 °C) OFF-state leakage current: < 5 μA at 30 V DC; ON-state saturation voltage: NPN: < 1.5 V; PNP : < 2 V Output Protection Protected against output short-circuit, continuous overload, transient overvoltages, and false pulse on power-up Output Response Time 25 µs 50 µs 150 µs 250 µs 500 µs Repeatability 12 µs 12 µs 30 µs 50 µs 80 µs Connections PVC-jacketed 2 m or 9 m (6.5 ft or 30 ft) 5-wire integral cable; or integral 5-pin M8 quick disconnect; or 150 mm (6 in) cable with a 5-pin M12 quick disconnect; or 150 mm (6 in) cable with a 5-pin M8 quick disconnect For Q3 or Q7 5-pin models, either a 5-pin M8 or a 6-pin M8 mating cordset may be used Construction Black ABS/polycarbonate alloy (UL94 V-0 rated) housing, clear polycarbonate cover Environmental Rating IP50, NEMA 1 Operating Conditions Temperature: –10 °C to +55 °C (+14 °F to +131 °F) Storage Temperature: –20 °C to +85 °C (–4 °F to +185 °F) Humidity: 90% at +60 °C maximum relative humidity (non-condensing) Required Overcurrent Protection Certifications WARNING: Electrical connections must be made by qualified personnel in accordance with local and national electrical codes and regulations. Industrial Control Equipment 3TJJ Overcurrent protection is required to be provided by end product application per the supplied table. Overcurrent protection may be provided with external fusing or via Current Limiting, Class 2 Power Supply. Supply wiring leads < 24 AWG shall not be spliced. For additional product support, go to www.bannerengineering.com. Supply Wiring (AWG) Required Overcurrent Protection (Amps) 20 5.0 22 3.0 24 2.0 26 1.0 28 0.8 30 0.5 Banner Engineering Corp. Limited Warranty Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following the date of shipment. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture which, at the time it is returned to the factory, is found to have been defective during the warranty period. This warranty does not cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product. THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED (INCLUDING, WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE, COURSE OF DEALING OR TRADE USAGE. This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP. BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT, WHETHER ARISING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY, NEGLIGENCE, OR OTHERWISE. Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any obligations or liabilities relating to any product previously manufactured by Banner Engineering Corp. Any misuse, abuse, or improper application or installation of this product or use of the product for personal protection applications when the product is identified as not intended for such purposes will void the product warranty. Any modifications to this product without prior express approval by Banner Engineering Corp will void the product warranties. All specifications published in this document are subject to change; Banner reserves the right to modify product specifications or update documentation at any time. Specifications and product information in English supersede that which is provided in any other language. For the most recent version of any documentation, refer to: www.bannerengineering.com. 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