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
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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
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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
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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:
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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
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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
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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.
For patent information, see www.bannerengineering.com/patents.
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