D10DPCFPQ

D10 Expert Series - Small Object Counter Datasheet Advanced sensor for small object counting • • • • • • • • • • Easy-to-set selectable threshold with automatic compensation algorithm Automatic compensation algorithm compensates for dust or contamination on the fiber optic array and for ambient temperature changes 16-bit microcontroller and 12-bit Analog-to-Digital converter (ADC) for high-performance, low-contrast sensing Easy-to-read 4-digit display for Health Mode, Percentage Blocked, Signal Level, or Counter Mode readout, plus indicators for a continuous readout of operating status (user configurable) Sleek, ultra-slim 10 mm housing, mounts to a standard 35 mm DIN rail Single discrete output plus Health Mode output to indicate preventative maintenance is required Three-mode power and speed selection to optimize detection reliability Dynamic event stretcher to ensure one output per event — especially for gel-cap style pills Visible red (680 nm) sensing beam Models available with 2 m or 9 m (6.5 ft or 30 ft) cable or integral Picostyle quick-disconnect Sensors Models Cables Discrete Outputs NPN D10DNCFP 2 m (6.5 ft) Cable D10DNCFPQ 6-pin Pico-style QD D10DPCFP 2 m (6.5 ft) Cable D10DPCFPQ 6-pin Pico-style QD PNP Fiber Optic Arrays Models 1 PFCVA-10X25-S PFCVA-10X25-E PFCVA-25X25-S PFCVA-25X25-E PFCVA-34X25-S PFCVA-34X25-E Detection Window Dimensions Fiber Exit Side exit 10 mm x 25 mm End exit Side exit 25 mm x 25 mm End exit Side exit 34 mm x 25 mm End exit Minimum Object Size 2 1.5 mm 3 mm 4 mm To order the 9 m (30 ft) cable model, add suffix "W/30" to the cabled model number. For example: D10DNCFP W/30. Models with a QD connector require a mating cable. 1 Custom fiber arrays and mounting configurations are possible. Consult factory for assistance with your small object counting application. 2 With 2% threshold offset percentage Original Document 146132 Rev. D 29 August 2014 146132 D10 Expert Series - Small Object Counter WARNING: Not To Be Used for Personnel Protection Never use this device as a sensing device for personnel protection. Doing so could lead to serious injury or death. This device does not include the self-checking redundant circuitry necessary to allow its use in personnel safety applications. A sensor failure or malfunction can cause either an energized or de-energized sensor output condition. Overview The D10 Expert Small Object Counter sensor is a high-performance plastic fiber optic amplifier that has been optimized for small object counting using through-beam fiber optic arrays. Fiber optic arrays emit and receive light over an area instead of a narrow beam. Having an area of light makes alignment and positioning control of the object less critical than using single point emitter and receiver fiber optic assemblies. Because the object only breaks part of the fiber optic array, reliable detection requires very precise thresholds, an auto compensation tracking algorithm, and high speed electronics to make split-second decisions. The setup and configuration of the advanced D10D sensor has been reduced to the act of applying power to the device with the fiber optic assemblies rigidly mounted in position. The user also has access to a comprehensive collection of setup and configuration parameters through the sensor’s advanced setup menu, but for most applications the default options provide superb performance and reliability. 1 3 2 Upon power-up, the clear-state light level is measured and appropriate switching thresholds are established, making the fiber optic sensor system a stable, fast, and reliable small object counter. The clear-state light level can be reset by performing a 2 second hold on the dynamic (+) push button or single-clicking the remote line. 4 Continued reliable operation is ensured as the thresholds adapt to changing signal levels over time using Banner Engineering’s auto compensation tracking algorithm. The sensor continuously tracks the clear-state light level and makes fine adjustments to the switching thresholds as required because of dust or contamination building up on the fiber optic array and for ambient temperature changes. 5 dynamic The sensor features either two NPN or two PNP outputs, depending on your model. Each output serves a different purpose. The discrete output 1 (white wire) switches whenever an object breaks the fiber optic array and can be used for counting. The Health Mode output 2 (black wire) switches when the fiber optic array becomes contaminated to a point that the auto compensation tracking algorithm cannot sufficiently adjust the thresholds to ensure reliable detection (see Health Mode Alarm on page 3). 6 The duration of the discrete output 1 (white wire) can be increased (stretched) to ensure accurate counting. The amount of increase is a user configurable percentage of the detection event duration; the default increase time is 50% more than the event duration. Banner calls this feature a Dynamic Event Stretcher (DES), and it prevents errant double counts of translucent gel-caps and other small objects of that type. The DES provides a “smart” OFF-delay that is independent of application speed and can be adjusted from 0% to 100% of the detection event duration. static Figure 1. D10D Features 1. Counting output indicator 2. Arrow icons 3. Health mode output indicator 4. 4-digit display 5. Light/dark operate, clock, and lock icons 6. Programming push buttons 2 www.bannerengineering.com - Tel: +1-763-544-3164 P/N 146132 Rev. D D10 Expert Series - Small Object Counter 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. 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 clear-state 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 clearstate light level (see Single-Point Window SET on page 7). Health Model Display Display Value 3 Outputs and Indicators System Status Discrete output 1: Operational 25 to 100 Health Mode output 2: Active OK: system operating normally Indicators: Arrow Icons 1 & 2 GREEN Discrete output 1: Operational 1 to 20 Health Mode output 2: Inactive Marginal: System operating normally; preventative maintenance recommended Indicators: Arrow Icon 1 Green; Arrow Icon 2 Red Discrete output 1: Forced to Blocked State (i.e. in dark operate, the output is conducting) 0 Health Mode output 2: Inactive Alarm: System not operational; system maintenance required Indicators: Arrow Icons 1 & 2 Red Programming Options Light/Dark Operate Selection. Toggle to select the condition for which the output will conduct: when the object is present or when the object is absent. Threshold Offset Percentage. 2%, 3%, 4%, 5%, 10% Dynamic Event Stretcher (DES) Selection. The output is held ON (OFF in Light Operate) for a percentage of time longer than the detection event duration. Options: 0%, 25%, 33%, 50%, 100% (e.g., If the Dynamic Event Stretcher was set at 50%, a 1 ms event would be stretched to 1.5 ms) Display Orientation. Normal or inverted Display Mode. Health Mode (100%–0%); Percentage Blocked (0%–100%); Signal Level (ADC value); or Counter Mode (0–9999) Power Level/Speed Selection. High-Speed (HS) (150 µs response, 50 µs repeatability); High-Power (HP) (225 µs response, 75 µs repeatability); or Super High-Power (SHP) (300 µs response, 100 µs repeatability) 3 Sensor display must be in Health Mode (see Sensor Setup on page 4) P/N 146132 Rev. D www.bannerengineering.com - Tel: +1-763-544-3164 3 D10 Expert Series - Small Object Counter Factory Default Settings. The following settings are preset at the factory; revert sensor to factory defaults using Advanced Setup procedure (see Advanced Setup on page 6) • Dark Operate (DO) • 50% DES • Health Mode Display • 2% Threshold Offset Percentage • Normal Display Orientation • High Speed (HS) Sensor Programming Programming Procedures. Use the Dynamic (+) and Static (-) buttons to access and set programming parameters. For remote programming, connect a switch or digital input to the gray wire (remote line); the length of the individual pulses is equal to the value T when 0.04 seconds ≤ T ≤ 0.8 seconds. Returning to RUN mode. Exit Setup mode by stepping through the entire Setup process (see Sensor Setup on page 4), by escaping out of the Setup process, or by exceeding the 60 second inactivity time-out. To escape out of the Setup process, press and hold both the Static (-) and Dynamic (+) buttons for 2 seconds. (For remote programming, press and hold the remote line for 2 seconds). The sensor always saves the selected settings and returns to Run mode. Sensor Setup • • • • Configures sensor display and operating parameters. Changes are updated instantly. Click Dynamic (+) or double-pulse remote line to select an option. Click Static (-) or single-pulse remote line to advance. Remote input pulse: 0.04 s ≤ T ≤ 0.8 s 1. Access Setup mode. Method Action Push Button Press and hold both the Dynamic (+) and Static (-) buttons concurrently for more than 2 seconds Remote Input Double-pulse the remote line Result • • • Arrow Icon 1 ON Red Arrow Icon 2 OFF Display shows “Threshold Offset Percentage” option. 2. Select the threshold offset percentage. Method Action Result Click Dynamic (+) to toggle between selections Push Button Remote Input Click Static (-) to save selection and advance to “Light/Dark Operate” 2% to 10% Threshold Offset Percentage: “t 2,” “t 3,” “t 4,” “t 5,” “t 10” Double-pulse remote line to toggle between selections Single-pulse the remote line to save selection and advance to “Light/Dark Operate" 3. Select light operate or dark operate. 4 www.bannerengineering.com - Tel: +1-763-544-3164 P/N 146132 Rev. D D10 Expert Series - Small Object Counter Method Push Button Action Result Click Dynamic (+) to toggle between selections Light Operate: • Display flashes “lo” • L icon ON Click Static (-) to save selection and advance to “Dynamic Event Stretcher (DES)” Double-pulse remote line to toggle between selections Remote Input Dark Operate: • • Single-pulse the remote line to save selection and advance to “Dynamic Event Stretcher (DES)” Display flashes “do” D icon ON 4. Select dynamic event stretcher (DES). Method Push Button Remote Input Action Result Click Dynamic (+) to toggle between selections OFF (No DES): • “d 0” • Clock icon OFF Click Static (-) to save selection and advance to “Display Mode” Double-pulse remote line to toggle between selections Single-pulse the remote line to save selection and advance to “Display Mode” 25%, 33%, 50%, or 100% DES: • “d 25,” “d 33,” “d 50,” “d 100,” • Clock icon ON 5. Select display mode. Method Action Result Click Dynamic (+) to toggle between selections Push Button Click Static (-) to save selection and advance to "Power/Speed" Health Mode: “HLth” Percentage Blocked: “Pctb” Remote Input Double-pulse remote line to toggle between selections Single-pulse the remote line to save selection and advance to “Power/Speed" Signal Level: “1234” Counter Mode: “Cntr” 6. Select the speed and power combination. P/N 146132 Rev. D www.bannerengineering.com - Tel: +1-763-544-3164 5 D10 Expert Series - Small Object Counter Method Push Button Action Result Click Dynamic (+) to toggle between selections Arrow Icons 1 and 2 ON Red To return to Run mode, click the Static (-) button OR To proceed to Advanced Setup, quad-click Static (-) button High-speed (150-µs response): “HS” High-power (225-µs response): “HP” Double-pulse the remote line to toggle between selections Remote Input Single-pulse the remote line to save selection and return to RUN mode OR Quad-click the remote line to proceed to Advanced Setup Super-high-power (300-µs response): “SHP” See Advanced Setup on page 6. Advanced Setup • • • • • Advanced adjustments to previously configured sensor display and operating parameters. Quad-click Static (-) or quad-pulse remote line before exiting “Speed and Power Combination” selection to enter this mode Click Dynamic (+) or double-pulse remote line to select an option. Click Static (-) or single-pulse remote line to advance. Changes are updated instantly. Remote input pulse: 0.04 s ≤ T ≤ 0.8 s 1. Enter Advanced Setup mode. Method Action Push Button From “Power and Speed” mode, quad-click Static (-) button Remote Input From “Power and Speed” mode, quad-pulse the remote line Result • • Arrow Icons 1 and 2 ON Red Display shows “Factory Default Settings” option. 2. Set to the factory default settings. Method Push Button Remote Input Action Result Click Dynamic (+) to toggle between selections Returns to factory default settings Click Static (-) to advance to “Display Orientation” Factory Default Settings Not Selected: Double-pulse the remote line to toggle between Display shows “Fd n” selections Factory Default Settings Selected: Display Single-pulse the remote line to advance to “Display Orientation” shows “Fd y” 3. Set the display orientation. Method Push Button Remote Input 6 Action Result Click Dynamic (+) to toggle between selections Inverts display to read “upside-down” Click Static (-) to return to RUN mode Double-pulse the remote line to toggle between selections Single-pulse the remote line to return to RUN mode Normal: Inverted: The icons do not invert. www.bannerengineering.com - Tel: +1-763-544-3164 P/N 146132 Rev. D D10 Expert Series - Small Object Counter Push Button Lockout • • Prevents unwanted adjustments or tampering of the push buttons. Push buttons can be enabled or disabled only from the remote line and only during normal RUN mode. Remote input pulse: 0.04 s ≤ T ≤ 0.8 s Method Action Result Push Button Not available with push-button programming Remote Input From RUN mode, quad-pulse the remote line to toggle between selections Push Buttons Disabled • Display flashes “loc” • Padlock icon appears • Sensor remains in RUN mode Push Buttons Enabled • Display flashes “uloc” • Padlock icon disappears • Sensor remains in RUN mode Gate Input The pink wire is configured as a gate input. When this wire is pulled low (e.g., to the sensor ground), it inhibits the outputs from switching while all other sensor functions continue to be enabled. This feature is useful for controlling when the outputs are allowed to change states. Gate input function response time is 1 millisecond. Single-Point Window SET A Window SET sets a single output condition that extends above and below the taught condition by a selectable offset percentage (2, 3, 4, 5, or 10%). Taught Condition In Dark Operate, a Window SET sets a single OFF condition that extends above and below the taught condition. All other conditions (lighter or darker) result in ON output. In Light Operate, a Window SET sets a single ON condition that extends above and below the taught condition. All other conditions (lighter or darker) result in OFF output. Output ON and OFF conditions can be reversed by changing Light/ Dark Operate status in SETUP mode. Remote input pulse: 0.04 s ≤ T ≤ 0.8 s P/N 146132 Rev. D Offset % Offset % Output ON Darkest (no signal) Output OFF Sensor positions window thresholds from the taught condition Output ON Most Light (saturated signal) Figure 2. Single-point Window Set and Offset Percentage (Dark Operate Shown) www.bannerengineering.com - Tel: +1-763-544-3164 7 D10 Expert Series - Small Object Counter Set Clear-State Light Level of Single-Point Window Method Push Button Remote Input Action Result 1. Verify the fiber optic array is clean and clear of any objects. Display turns OFF and Arrow Icons 1 and 2 toggle 3 times green while the sensor is optimizing system settings. 2. Press and hold Dynamic (+) button for more than 2 seconds. TEACH • • • • conditions acceptable: Display flashes “PASS” Sensor returns to Run mode with new settings. Arrow Icons 1 and 2 turn ON Green Health Mode output 2 Active TEACH • • • conditions unacceptable: Display flashes “FAIL” Arrow Icons 1 and 2 turn ON Red Health Mode output 2 Inactive 1. Make sure fiber optic array is clean and clear of any objects. 2. Single-pulse the remote line. Wiring Diagrams Wiring for quick disconnect (QD) models are functionally identical. NPN Output Models bu bn wh bk load − 12–24V dc + 1 2 health gy pk PNP Output Models Teach Gate bn bu wh bk gy pk load health + 12–24V dc − 1 2 Teach Gate D10D...Port Locations Slides Up to Release Fibers Plastic Fiber Emitter Port Plastic Fiber Receiver Port 8 www.bannerengineering.com - Tel: +1-763-544-3164 P/N 146132 Rev. D D10 Expert Series - Small Object Counter Specifications Required Fiber Optics PFCVA models (Custom fiber arrays and mounting configurations are possible. Consult factory for assistance with your small object counting application.) Sensing Beam Visible red, 680 nm Supply Voltage and Current 12 to 24 V dc (10% maximum ripple) at less than 65 mA, exclusive of load Supply Protection Circuitry Protected against reverse polarity and transient voltage Output Protection Circuitry Protected against false pulse on power-up and continuous short-circuit Output Configuration 2 NPN or 2 PNP, depending on model Output Rating 150 mA maximum load OFF-state leakage current: < 10 µA at 24 V dc ON-state saturation voltage: NPN < 1.5 V at 150 mA load; PNP < 2.5 V at 150 mA load Output Response Time Programmable, 150 µs, 225 µs, 300 µs NOTE: < 1 second delay on power-up; outputs do not conduct during this time. Adjustments Push-button or remote programming of threshold offset percentage, light/dark operate, Dynamic Event Stretcher (DES), display, and power/speed Installation 35 mm DIN rail or included mounting bracket Indicators Four-digit digital display, 2 arrow icons, push-button lockout, Dynamic Event Stretcher, light/dark operate selection, and 2 amber output LEDs Certifications Construction Black ABS/polycarbonate alloy (UL94 V-0 rated) housing, clear polycarbonate cover Environmental Rating NEMA 1, IEC IP50 Operating Conditions Temperature: –20 to 55 °C (–4 to 131 °F) Storage Temperature: –20 to 80 °C (–4 to +75 °F) Max. Rel. Humidity: 90% at 50 °C (non-condensing) Number of Devices, Stacked Ambient Temp Rating Load Specification 3 55 °C 150 mA 7 50 °C 50 mA 10 45 °C 50 mA Connections PVC-jacketed 2 m or 9 m (6.5 ft or 30 ft) 6-wire integral cable or integral 6-pin Pico-style quick-disconnect D10D...Sensor Dimensions 10.5 ± 0.2 mm (typ.) (0.41") 35.9 mm (1.41") 7.6 mm 0.30" 9.8 mm (0.39") Mounting Bracket (included) 61.3 mm (2.42") 68.1 mm (2.68") P/N 146132 Rev. D www.bannerengineering.com - Tel: +1-763-544-3164 9 D10 Expert Series - Small Object Counter Included Bracket Dimensions 5.0 mm (0.20") 35.1 mm (1.38") 15.2 mm (0.60") M3 Hardware included: Lock Washer (2) Flat Washer (2) Screws (2) Hex Nuts (2) 8.6 mm (0.34") 10.0 mm (0.39") 5.0 mm (0.20") 2x 3.5 mm (0.14") 2.5 mm (0.10") 25.4 mm (1.00") 16.0 mm (0.63") 2 x ø3.3 mm (0.13") 2x ø3.2 mm (0.13") 10.0 mm (0.39") 2x C’sink ø8.0 mm (0.31") 3.2 mm (0.13") deep ø4.4 mm (0.18") thru Fiber Optic Array Dimensions 14.5 mm [0.57”] 83 mm [3.27”] 42 mm [1.65”] 30 mm [1.18”] 10 mm [0.39”] 25 mm [0.98”] 4x 3.2 mm dia [0.13”] 75 mm [2.95”] Figure 3. PFCVA-10X25-S and PFCVA-10X25-E 10 www.bannerengineering.com - Tel: +1-763-544-3164 P/N 146132 Rev. D D10 Expert Series - Small Object Counter 14.5 mm [0.57”] 83 mm [3.27”] 42 mm [1.65”] 30 mm [1.18”] 25 mm [0.98”] 4x 3.2 mm dia [0.1260”] 25 mm [0.98”] 75 mm [2.95”] Figure 4. PFCVA-25X25-S and PFCVA-25X25-E 14.5 mm [0.57”] 83 mm [3.27”] 25 mm [0.98”] 34 mm [1.34”] 30 mm [1.18”] 42 mm [1.65”] 4x 3.2mm dia [0.1260”] 75 mm [2.95”] Figure 5. PFCVA-34X25-S and PFCVA-34X25-E P/N 146132 Rev. D www.bannerengineering.com - Tel: +1-763-544-3164 11 D10 Expert Series - Small Object Counter Accessories 6-Pin Snap-on M8/Pico-Style Cordsets Model Length PKG6Z-2 2 m (6.5 ft) PKG6Z-9 9 m (30 ft) Style Dimensions Pinout ø10 mm max. (0.4") Straight 3 28 mm max. (1.1") PKW6Z-2 2 m (6.5 ft) PKW6Z-9 9 m (30 ft) 6 2 25 mm max. (1.0") 20 mm (0.8") Right-angle 4 5 1 1 2 3 4 5 6 - brown = White = Blue = Black = Gray = Pink ø12 mm max. (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. www.bannerengineering.com - Tel: +1-763-544-3164