BMRL6032A

A-GAGE® MINI-ARRAY® Measuring Light Screen System Instruction Manual Original Instructions 43298 Rev. H 27 August 2019 © Banner Engineering Corp. All rights reserved 43298 A-GAGE® MINI-ARRAY® Measuring Light Screen System Contents 1 Features ..........................................................................................................................................................................3 1.1 MINI-ARRAY Models 2 Overview ...................................................................................................................................................................... 4 .........................................................................................................................................................................6 2.1 System Features ............................................................................................................................................................................. 7 2.2 Sensing Response .......................................................................................................................................................................... 7 2.3 Supplied System Software ............................................................................................................................................................. 7 3 Specifications ................................................................................................................................................................. 9 3.1 Specifications for the Emitter/Receiver Pairs ................................................................................................................................. 9 3.2 Dimensions for the Emitters and Receivers .....................................................................................................................................9 3.3 Specifications for the MAC Controllers ......................................................................................................................................... 10 3.4 Dimensions for the Controller ....................................................................................................................................................... 11 4 Installation Instructions .................................................................................................................................................12 4.1 Emitter and Receiver Mounting ..................................................................................................................................................... 12 4.2 Controller Mounting ...................................................................................................................................................................... 13 4.3 Emitter and Receiver Wiring ......................................................................................................................................................... 13 4.4 Controller and Output Wiring ........................................................................................................................................................ 13 4.4.1 MAC-1 Controller Wiring ....................................................................................................................................................... 13 4.4.2 MACP-1 Controller Wiring .....................................................................................................................................................14 4.4.3 MACN-1 Controller Wiring .....................................................................................................................................................14 4.4.4 MACV-1 Controller Wiring ..................................................................................................................................................... 15 4.4.5 MACI-1 Controller Wiring ...................................................................................................................................................... 15 4.4.6 MAC16P-1 Controller Wiring .................................................................................................................................................16 4.4.7 MAC16N-1 Controller Wiring .................................................................................................................................................16 4.5 System Power Wiring ....................................................................................................................................................................17 4.6 Gate Wiring ................................................................................................................................................................................... 17 4.7 Serial Communication Wiring ....................................................................................................................................................... 17 5 Configuration Instructions ............................................................................................................................................ 18 5.1 Install the Software ....................................................................................................................................................................... 18 5.2 Define the Communication ........................................................................................................................................................... 18 5.3 Alignment ....................................................................................................................................................................................... 18 5.4 Parameter Setup Files (PSFs) ....................................................................................................................................................... 19 5.4.1 Assigning the Analysis Mode ................................................................................................................................................ 20 5.4.2 Configuring the Outputs ........................................................................................................................................................ 21 5.4.3 Configuring the Blanking Specifications ................................................................................................................................ 24 5.4.4 Configuring the Scanning Method ........................................................................................................................................ 24 5.4.5 Configuring the Control Mode ...............................................................................................................................................25 5.4.6 Configuring the Serial Communication ................................................................................................................................. 25 5.4.7 PSF Assignment and Storage ............................................................................................................................................... 26 6 Operating Instructions .................................................................................................................................................. 28 6.1 Status Indicators for the MINI-ARRAY Sensors ........................................................................................................................... 28 6.2 Status Indicators for the MACx-1 Series Controllers ....................................................................................................................28 6.3 Diagnostics Program .................................................................................................................................................................... 29 7 Additional Information .................................................................................................................................................. 31 7.1 Host Mode Command .................................................................................................................................................................. 31 7.2 Serial Data Format ........................................................................................................................................................................ 31 7.3 ASCII Format Data Transmission ..................................................................................................................................................31 7.4 Binary Format Data Transmission .................................................................................................................................................32 8 Accessories ................................................................................................................................................................... 33 8.1 Anti-Vibration Mounting Kits .........................................................................................................................................................33 9 Product Support and Maintenance .............................................................................................................................. 34 9.1 Contact Us .....................................................................................................................................................................................34 9.2 Banner Engineering Corp. Limited Warranty ................................................................................................................................ 34 A-GAGE® MINI-ARRAY® Measuring Light Screen System 1 Features • • • • • • • • • • Measuring Light Screen system for inspection and profiling applications Modular system with compact controller and a variety of BMEL/BMRL series MINI-ARRAY emitters and receivers Sensors available with either 9.5 mm (3/8 in) or 19.1 mm (3/4 in) beam spacing and with array lengths from 6 in to 4 ft (in 6 in increments), plus 5 ft and 6 ft models Controller is programmable for any one or two of ten measurement modes (depending on model) and any one of four scanning modes, using a computer running Windows® XP, Vista, or 7, and the Banner-supplied software Software is also supplied for display of error analysis (via controller selfdiagnostics) and for sensor alignment System status, including alignment, is displayed via LED indicators on the controller and on the receivers Controller may be programmed for blanking to ignore activity in one or two fields along the length of the array Programmable hysteresis at the high and/or low limit of each measurement area provides smoothing of output response; also programmable for number of consecutive scans before an output update Separate gate input (e.g., from a presence sensor) allows control of scan initiation Supports serial communication with a computer or PLC via RS-232C interface; enables a computer or PLC to process scan data and/or initiate scans; serial data may be either ASCII or binary WARNING: • Do not use this device for personnel protection • Using this device for personnel protection could result in serious injury or death. • This device does not include the self-checking redundant circuitry necessary to allow its use in personnel safety applications. A device failure or malfunction can cause either an energized (on) or de-energized (off) output condition. www.bannerengineering.com - Tel: + 1 888 373 6767 3 A-GAGE® MINI-ARRAY® Measuring Light Screen System 1.1 MINI-ARRAY Models Each A-GAGE MINI-ARRAY system must include one controller and an emitter/receiver pair of matching length and resolution. Configure and monitor the system using the supplied software and a user-supplied PC-compatible computer. These MAC series controllers operate on 16 to 30 V dc and have one sensor pair input and one gate input. MAC Series Controllers Models Output 1 Output 2 MAC-1 Discrete Reed Relay Discrete NPN MACN-1 Discrete NPN MACP-1 Discrete PNP MACV-1 Two Analog (0 to 10V dc Sourcing) MACI-1 Two Analog (4 to 20 mA Sinking) Serial Output Scan Analysis Modes PSF Parameter Part Number 8 43989 10 59114 RS-232 and RS-485 Discrete PNP Discrete NPN RS-232 MAC16N-1 16 Discrete NPN Outputs MAC16P-1 16 Discrete PNP Outputs The dimensions for the MAC series controllers listed are: 110 × 100 × 75 mm (4.3 in × 3.9 in × 3 in). 4 www.bannerengineering.com - Tel: + 1 888 373 6767 A-GAGE® MINI-ARRAY® Measuring Light Screen System Emitter/Receiver Pairs -- 19.1 mm (3/4 inch) Beam Spacing (16 beams/foot) Emitter Receiver Array Length Total Beams BMEL616A BMRL616A 133 mm (5.25 inch) 8 BMEL1216A BMRL1216A 286 mm (11.25 inch) 16 BMEL1816A BMRL1816A 438 mm (17.25 inch) 24 BMEL2416A BMRL2416A 591 mm (23.25 inch) 32 BMEL3016A BMRL3016A 743 mm (29.25 inch) 40 BMEL3616A BMRL3616A 895 mm (35.25 inch) 48 BMEL4216A BMRL4216A 1048 mm (41.25 inch) 56 BMEL4816A BMRL4816A 1200 mm (47.25 inch) 64 BMEL6016A BMRL6016A 1505 mm (59.25 inch) 80 BMEL7216A BMRL7216A 1810 mm (71.25 inch) 96 Emitter/Receiver Pairs -- 9.5 mm (3/8 inch) Beam Spacing (32 beams/foot) Emitter Receiver Array Length Total Beams BMEL632A BMRL632A 143 mm (5.62 inch) 16 BMEL1232A BMRL1232A 295 mm (11.62 inch) 32 BMEL1832A BMRL1832A 448 mm (17.62 inch) 48 BMEL2432A BMRL2432A 600 mm (23.62 inch) 64 BMEL3032A BMRL3032A 752 mm (29.62 inch) 80 BMEL3632A BMRL3632A 905 mm (35.62 inch) 96 BMEL4232A BMRL4232A 1057 mm (41.62 inch) 112 BMEL4832A BMRL4832A 1210 mm (47.62 inch) 128 BMEL6032A BMRL6032A 1514 mm (59.62 inch) 160 BMEL7232A BMRL7232A 1819 mm (71.62 inch) 192 Controller-to-Sensor Cables (two required per system) Model Length QDC-515C 4.6 m (15 ft) QDC-525C 7.6 m (25 ft) QDC-550C 15.2 m (50 ft) MAQDC-575C 22.7 m (75 ft) MAQDC-5100C 30.3 m (100 ft) MAQDC-5125C 37.9 m (125 ft) MAQDC-5150C 45.5 m (150 ft) www.bannerengineering.com - Tel: + 1 888 373 6767 QD Connector 5-pin Mini-style straight 5 A-GAGE® MINI-ARRAY® Measuring Light Screen System 2 Overview The Banner A-GAGE® MINI-ARRAY measuring light screen is ideal for applications such as on-the-fly product sizing and profiling, edge-guiding and center-guiding, loop tensioning control, hole detection, parts counting, die ejection verification, and similar uses. A typical MINI-ARRAY System consists of the following components: • Controller module • Emitter • Receiver • Two interconnecting cables Sensors are available in array lengths from 6 inches to 4 feet (in 6 inch increments), plus 5 foot and 6 foot array models. Sensors are available with either 9.5 mm (3/8 inch) or 19.1 mm (3/4 inch) beam spacing, which translates to either 32 or 16 beams per foot of array length. Sensors with 3/8-inch beam spacing have a sensing range of up to 6 m (20 ft). Sensors with 3/4-inch beam spacing have a sensing range of up to 17 m (55 ft); 5 ft and 6 ft arrays have shorter ranges. Some typical MINI-ARRAY applications are: 6 Paint Booth Profiling Box Profiling Inspection Applications Edge Guiding www.bannerengineering.com - Tel: + 1 888 373 6767 A-GAGE® MINI-ARRAY® Measuring Light Screen System 2.1 System Features Built-in features simplify the operation of the A-GAGE MINI-ARRAY system. Programmable beam blanking accommodates machine components or other fixtures that must remain in or move through the light screen. Blanking is set by using the included configuration software. See ######## for more information. Built-in diagnostic programming and easy-to-see indicators on the sensors and the control module make alignment and troubleshooting easy. The emitter has a red LED that signals proper operation. The receiver has three bright LEDs: green signals that the sensors are properly aligned; yellow signals marginal alignment; and red signals misalignment or a blocked condition. The control module has seven status indicators: five red LEDs signal when outputs are conducting, Alarm output conducting, and gate signal received; a green LED signals that the sensors are properly aligned. DIAG 1, 2, and 3 LEDs indicate system status. A key to the diagnostics codes is printed on the side of the control module for simplified troubleshooting. The MINI-ARRAY System provides a wide selection of sensing and output options, including: measurement (“scan analysis”) modes and scanning methods that can determine the target object’s location, overall size, total height or total width. Scanning may be continuous or controlled by a host process controller or a gate sensor. Some models (MAC1, MACP, MACN) support RS-485, where up to 15 systems may be networked. Emitter Receiver DIN-Rail-Mountable Control Module Red Discrete Output #1 LED Red Alarm (Discrete Output #2) LED MINI-ARRAY CONTROLLER MAC-1 RS-232 15 OUT 1 DIAG 1 ALARM DIAG 2 GATE DIAG 3 ALIGN 14 13 12 11 10 9 8 T/R 30V + + 500mA 150mA RS485 10-30V DC Max GATE Max. OUT 1 ALARM 7 6 5 4 2 1 T/R DRN COM +12V WH BK F1 BU BR L2 L1 16-30V DC 1.2A Max. 5 Wires RS-232 Red Gate LED EMTR Green Align LED 3 15 14 13 12 11 10 9 2 - TX 3 - RX 5 - COM RCVR 8 7 6 5 4 POWER 3 2 1 Red Operational LED Green Alignment LED Red Blocked LED Yellow Marginal Alignment LED RS-232 Port Figure 1. A-GAGE MINI-ARRAY System Features 2.2 Sensing Response Sensing response is a function of the number of beams interrogated (steps) per scan of the array. The time per step is 55 μs (0.000055 seconds). As a result, dense arrays (for example with 3/8 inch beam spacing) yield the highest sensing resolution. Arrays with wider (3/4 inch) beam spacing offer faster sensing response. 2.3 Supplied System Software The supplied software program, used to configure each system control module, may be run on any PC running Windows® XP, Vista, or 7. The menu-driven program walks the user through the many scanning and output options. After the desired options are selected, the user can save the combination of selections in a Parameter Setup File (PSF), and store it in the control module’s non-volatile memory. Any number of PSFs may be stored in the computer and recalled as needed. www.bannerengineering.com - Tel: + 1 888 373 6767 7 A-GAGE® MINI-ARRAY® Measuring Light Screen System The software also provides alignment and diagnostics routines. An Alignment screen displays the individual status of each beam in the light screen, as well as the total number of beams in the system, and totals of beams blocked, made, and blanked. Built-in system diagnostics can be used to assess emitter and receiver hardware errors. 8 www.bannerengineering.com - Tel: + 1 888 373 6767 A-GAGE® MINI-ARRAY® Measuring Light Screen System 3 Specifications 3.1 Specifications for the Emitter/Receiver Pairs Range (9.5 mm Beam Spacing) 0.6 m to 6.1 m (2 ft to 20 ft) for sensors < 4 ft 0.6 m to 4.6 m (2 ft to 15 ft) for sensors > 4 ft Maximum range is specified at the point where 3× excess gain remains. Range (19.1 mm Beam Spacing) 0.9 m to 17 m (3 ft to 55 ft) for sensors < 4 ft 0.9 m to 14 m (3 ft to 45 ft)for sensors > 4 ft Maximum range is specified at the point where 3× excess gain remains. Minimum Object Sensitivity (9.5 mm Beam Spacing) 19.1 mm (0.75 in) Interlaced Mode: 12.7 mm (0.5 in) Assumes sensing is in middle one-third of scanning range. Minimum Object Sensitivity (19.1 mm Beam Spacing) 38.1 mm (1.5 in) Interlaced Mode: 25.4 mm (1 in) Assumes sensing is in middle one-third of scanning range. Supply Voltage and Current (Emitter) 0.10 amps at 12 V dc Maximum current is for a 6 ft sensor. Supply Voltage and Current (Receiver) 9.5 mm beams: 0.75 amps at 12 V dc maximum 19.1 mm beams: 0.50 amps at 12 V dc maximum Maximum current is for a 6 ft sensor. Status Indicators (Emitter) Red LED lights for proper operation Construction Aluminum housing with black anodized finish; acrylic lens cover Sensor Scan Time 55 microseconds per beam, plus 1 millisecond processing time per scan Assumes straight scan, continuous scan, and TBB mode Environmental Rating IEC IP65 Operating Conditions –20 °C to +70 °C (–4 °F to +158 °F) 95% maximum relative humidity (non-condensing) Status Indicators (Receiver) Green: sensors aligned (> 3× excess gain) Amber: marginal alignment (1×-3× excess gain) Red: sensors misaligned or beam(s) blocked Connections Emitter and receiver connect to controller using two 5-conductor quickdisconnect cables (one each for emitter and receiver), ordered separately. Cables measure 8.1 mm (0.32 in ) dia., and are shielded and PVCjacketed; conductors are 20-gauge. Use only Banner cables, which incorporate a "“twisted pair” for noise immunity on RS-485 data communication lines. Emitter and receiver cables may not exceed 250 ft each. 3.2 Dimensions for the Emitters and Receivers With Mounting Bracket Flanges Out With Mounting Bracket Flanges In 38.1 mm square [1.5”] L2 L3 L1 X 2.5 mm [0.10”] 18.3 mm [0.72”] 10.2 mm [0.4”] Housing Length Emitter/Receiver Models Distance Between Bracket Holes L1 L2 L3 BMEL6..A / BMRL6..A 201 mm (7.9 in) 233.9 mm (9.21 in) 177 mm (6.97 in) BMEL12..A / BMRL12..A 356 mm (14 in) 389.7 mm (15.35 in) 332.8 mm (13.1 in) www.bannerengineering.com - Tel: + 1 888 373 6767 9 A-GAGE® MINI-ARRAY® Measuring Light Screen System Housing Length Distance Between Bracket Holes Emitter/Receiver Models L1 L2 L3 BMEL18..A / BMRL18..A 505 mm (19.9 in) 538.7 mm (21.22 in) 481.8 mm (18.97 in) BMEL24..A / BMRL24..A 659 mm (26 in) 693.2 mm (27.31 in) 636.3 mm (25.05 in) BMEL30..A / BMRL30.A 810 mm (31.9 in) 843.5 mm (33.23 in) 786.6 mm (30.97 in) BMEL36..A / BMRL36.A 963 mm (37.9 in) 997.4 mm (39.29 in) 940.5 mm (37 in) BMEL42..A / BMRL42.A 1115 mm (43.9 in) 1148 mm (45.2 in) 1091 mm (43 in) BMEL48..A / BMRL48.A 1267 mm (49.9 in) 1301 mm (51.2 in) 1244 mm (49 in) BMEL60..A / BMRL60..A 1572 mm (61.9 in) 1606 mm (63.2 in) 1549 mm (61 in) BMEL72..A / BMRL72..A 1877 mm (73.9 in) 1910 mm (75.2 in) 1853 mm (73 in) Beam Spacing X (Distance for First Optical Channel) 9.5 mm (3/8 in) 38.1 mm (1.5 in) 19.1 mm (3/4 in) 42.9 mm (1.69 in) 3.3 Specifications for the MAC Controllers Supply Voltage and Current 16 to 30 V dc at 1.25 amps maximum (see current requirements for sensors) Controller alone (without sensors connected) requires 0.1 amp Inputs MINI-ARRAY sensor input (5 connections); emitter and receiver wire in parallel to five terminals GATE input: Optically-isolated, requires 10 to 30 V dc (7.5K input impedance) for gate signal Discrete Outputs (MAC-1) Output 1 (OUT 1): Reed relay contact rated 125 V ac/dc max., 10 VA max. resistive load (non-inductive) Output 2 (ALARM): Open collector NPN transistor rated 30 V dc max., 150 mA max, short-circuit protected (may be configured as a second data analysis output, system alarm output, or scan trigger output for a parallel array) OFF-STATE Leakage Current: < 10 μA at 30 V dc ON-STATE Saturation Voltage: