A-GAGE® High-Resolution MINI-ARRAY® Instruction Manual

High-Resolution MINI-ARRAY Features• Excelsathigh-speed,preciseprocessmonitoringandinspectionapplications

• Acomprehensivecombinationofscanningmodesandoutputs:

–10measurement(“ScanAnalysis”)modes –3scanningmethods –Beamblanking –Selectablecontinuous,gatedorhost-controlledscaninitiation

–Programmablehysteresisforhighandlowlimits

–Serialcommunicationoptions• Storablescanningprogramseliminatereprogrammingforrepeatedapplications

• Non-volatilememorystoresalignmentsettings

• AllmodelswithbothAnalogandDiscreteoutputs

• AnalogoutputNullsetting• Lowcost,comparedwithsimilarsystems• Precisionsensorshavea380mmto1.8m(15"to6')workingrange

• Widefieldofview,easilyaligned• Alignmentroutineequalizesgainofeachbeamforreliable2.5mm(0.10")objectdetectionthroughoutthearray

• HostcomputerorPLCmaybeusedtoinitiatescansand/orprocessscandata

• Uniqueaddressesforupto15controlmodulesononeEIA-485PartyLine

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A-GAGE® High-Resolution MINI-ARRAY® Instruction ManualFor controllers with 2 analog and 2 discrete outputs

Printed.in.USA. 04/12 P/N 64118 rev.C

971410thAvenueNorth•Minneapolis,MN55441Phone:763.544.3164• Fax:763.544.3213

Email:[email protected]

¤

WARNING . . .Not To Be Used for Personnel Protection

ThesesensorsdoNOTincludetheself-checkingredundantcircuitrynecessarytoallowtheiruseinpersonnelsafetyapplications.Asensorfailureormalfunctioncancauseeitheranenergizedorde-energizedoutputcondition.ConsultyourcurrentBannerSafetyProductscatalogforsafetyproductswhichmeetOSHA,ANSIandIECstandardsforpersonnelprotection.

!

P/N64118rev.B2Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164

3Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164

P/N64118rev.B

Table of Contents

Banner Engineering Corp. •Minneapolis,U.S.A.www.bannerengineering.com•Tel:763.544.3164

1. System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 SystemComponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 SystemFeatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.3 TypicalApplications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.1 EmitterandReceiverSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2 ControlModuleSpecifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3. Installation and Mechanical Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1 EmitterandReceiverMounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.2 ControlModuleMounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.3 Hookups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.3.1 EmitterandReceiverHookups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3.2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3.3 Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. Software Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5. Control Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1 CommunicationsSetup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1.1 PingRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.1.2 FactorySettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2 SystemAlignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.1 Push-buttonAlignmentRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.2 SoftwareAlignmentRoutine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.2.3 Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.3 ProgrammingControlModuleResponse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5.3.1 SelectedControllerandSerialConnection. . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3.2 ControlModeSelection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3.3 ScanningMethod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.3.4 ScanAnalysisModeSelection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.3.5 AnalogOutputConfiguration(AnalysisModeAssignment). . . . . . . . . . . . 26 5.3.6 ZeroValue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3.7 DiscreteOutputConfiguration(AnalysisModeAssignment). . . . . . . . . . . 28 5.4 SerialCommunicationwithaHostController . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.1 SerialDataTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.2 TransmissionType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.4.3 SerialOptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.5 TransferofPSFtotheControlModule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.5.1 SavingandRecallingPSFFiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5.2 PSFOutputAnalysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5.3 QuitandExit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6. System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1 DiagnosticsIndicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.2 DiagnosticsRoutine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Appendix A: Data Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.1 HostModeCommandString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.2 SerialDataFormatandHeaderString . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 A.2.1 ASCIIFormatDataTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A.2.2 BinaryFormatDataTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A.3 MaxMeasureModeCommandString. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Appendix B: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

P/N64118rev.B

System Description


1. System Description

TheA-GAGE®High-ResolutionMINI-ARRAY®measuringlightscreenisidealforapplicationssuchason-the-flyproductsizingandprofiling,edge-guidingandcenter-guiding,looptensioningcontrol,holedetection,partscountingandsimilaruses.

1.1 System Components

AtypicalA-GAGEHigh-ResolutionMINI-ARRAYSystemhasfivecomponents:ahigh-resolutionemitter/receiverpair,eachwithquick-disconnect(QD)connectors;oneoffourcompactcontrolmodules;andquick-disconnectcablestoconnectthem.SoftwareisincludedtointerfaceanyPC-compatiblecomputer(runningWindows®X, Vista, or 7)withthecontrolmoduleforSystemconfiguration.AhostcomputerorPLCmaybeusedtocontroland/orreceiveinputfromtheSystem.

Sensorsareavailablein12arraylengthsfrom163mmto1951mm(6.4"to76.8"),in163mm(6.4")increments,aslistedinthetableonpage5.TheemitterhastwocolumnsofinfraredLEDsspaced5mm(0.2")apart.Thecolumnsareseparatedby7.5mm(0.3")andarestaggeredfromeachotherby2.5mm(0.1").Thereceiverisconfiguredoppositetotheemitter,withtheidenticallengthandbeamspacing.Thishigh-resolutionsensorpairiscapableofdetectinga12.7-mmlongby2.54-mmdiameter(0.5"by0.1"dia.)cylindricalrod(heldperpendiculartothesensor).Thesensorshaveawidefieldofviewandareeasilyaligned,withaworkingrangeof380mmto1.8m(15"to6').

Eachofthefourversatilemicrocontroller-basedcontrolmodulesareconfiguredusingaPC-compatiblecomputerrunningWindows XP, Vista, or 7,andthesuppliedsoftware,viathebuilt-inRS-232interface.

psanchez

Sticky Note

Marked set by psanchez


P/N64118rev.B

System Description

Emitter/Receiver Model

MAHE64AEmitterMAHR64AReceiver 1626mm(64.0")

MAHE6AEmitterMAHR6A Receiver

MAHE77AEmitterMAHR77AReceiver 1951mm(76.8")

MAHE13A EmitterMAHR13A Receiver

MAHE19A EmitterMAHR19A Receiver

MAHE26A EmitterMAHR26AReceiver

MAHE32A EmitterMAHR32AReceiver

MAHE38AEmitterMAHR38A Receiver

MAHE45AEmitterMAHR45AReceiver




Array Length Y*

163mm(6.4")

325mm(12.8")

488mm(19.2")

650mm(25.6")

813mm(32.0")

975mm(38.4")

1138mm(44.8")

1300mm(51.2")

1463mm(57.6")

1788mm(70.4")

640

768

Total Beams

64

128

192

256

320

384

448

512

576

704

Emitter and Receiver Models

Cables

Configure and monitor the System with the supplied software and any PC-compatible computer (running Windows® XP, Vista, or 7), via an RS-232 cable.

High-Resolution Receiver

High-Resolution Emitter

DIN-Rail Mountable Control Module

Figure 1-1. A-GAGE High-Resolution MINI-ARRAY System components


ControllerModel

Solid-StateDiscrete Outputs

Analog Outputs

MAHCVP-1 2PNP (2)0-10VSourcing

MAHCVN-1 2NPN (2)0-10VSourcing

MAHCIP-1 2PNP (2)4-20mASinking

MAHCIN-1 2NPN (2)4-20mASinking

Quick-Disconnect Cables

Communication Cables

CableModel Description

Sensor CablesQDC-515C 4.6m(15')Cable,straightQDconnector

QDC-525C 7.6m(25')Cable,straightQDconnector

QDC-550C 15.2m(50')Cable,straightQDconnector

Communication CablesMASC 2m(6.5')DB9,straightRS-232cable

Control Module Models

P/N64118rev.B

System Description

6

Figure 1-2. A-GAGE High-Resolution MINI-ARRAY System features

1.2 System Features

Built-infeaturessimplifytheoperationoftheA-GAGEHigh-ResolutionMINI-ARRAYsystem.High-resolutionemittersandreceivers,availablein12lengths,featuretwocloselyspacedcolumnsofbeamstoprovideaprecise,high-resolutionlightscreenforexactingapplications.TheAlignmentroutineautomaticallyequalizestheexcessgainofeachbeamforreliable2.5-mm(0.10")objectdetectionthroughoutthearrayandstoresthisdatainnon-volatilememory.TheAlignmentroutineneednotbeperformedagainunlessthesensingapplicationchanges,oriftheemitterand/orreceiverismoved.Programmablebeamblankingaccommodatesmachinecomponentsorotherfixturesthatmustremaininormovethroughthelightscreen.Blankingmaybesetautomaticallyaspartoftheinitialsetup,orbyusingtheincludedconfigurationsoftware.

Built-indiagnosticprogrammingandeasy-to-seeindicatorsonthesensorsandthecontrolmodulemakealignmentandtroubleshootingeasy(Figure1-2).TheemitterhasaredLEDthatsignalsproperoperation.ThereceiverhasthreebrightLEDs:greensignalsthatthesensorsareproperlyaligned;yellowsignalsmarginalalignment;andredsignalsmisalignmentorablockedcondition.Thecontrolmodulehasfourstatusindicators:3redLEDssignaldiscreteoutput#1conducting(seesection5.3.5formoreinformationonoutputs),Alarmoutput(discreteoutput#2)conducting,andgatesignalreceived;agreenLEDsignalsthatthesensorsareproperlyaligned.AsegmentedLEDDiagnosticsIndicatorprovidesdetailedsystemstatususingsingle-digitcodes;a“period”intheindicatorwindowindicatesthepresenceofblanking.Akeytothediagnosticscodesisprintedonthesideofthecontrolmoduleforsimplifiedtroubleshooting.

TheA-GAGEHigh-ResolutionMINI-ARRAYSystemprovidesawideselectionofsensingandoutputoptions,including:measurement(“scananalysis”)modesandscanningmethodsthatcandeterminethetargetobject’slocation,overallsize,totalheightortotalwidth.Scanningmaybecontinuousorcontrolledbyahostprocesscontrolleroragatesensor.Upto15systemsmaybenetworked.

High-Resolution Emitter

DIN-Rail-Mountable Control Module

High-Resolution Receiver

HIGH RESOLUTION MINI-ARRAY CONTROLLER

ALIGNMENTSWITCH

POWER

POWER

DIAGNOSTICSINDICATOR

2 - TX3 - RX5 - COM

RS-232

MAHCVP-1

OUTP

UT

ALAR

M

GATE

ALIG

N

1

+ –

+ –

16-30V dc1A MAX

10-30VDCGATE

D OUT 1 150mA MAX

0-10VOLTS25mA (MAX)

V OUT 1

EMTR RCVR

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1 +12V COM DRN T/R T/R

BR BU BK WH

TX TX+ –

10-30VDCALIGN

0-10VOLTS25mA (MAX)

V OUT 2+V

ALARM150mA MAX

+V

7.6 mm (0.30")

2.5 mm(0.10")

5.1 mm(0.20")

Diagnostics Indicator

Alignment Button

Red Discrete Output #1 LED

Red OperationalLED

Green Alignment LEDRed Blocked LED

Yellow MarginalAlignment LED

Red Alarm (Discrete Output #2) LEDRed Gate LED

Green Align LED

RS-232 Port



P/N64118rev.B

System Description


Figure 1-3. Typical applications for the A-GAGE High-Resolution MINI-ARRAY System

Log Profiling for Lumber Optimization Box Profiling

Maintaining Centering of Opaque Rolled Goods Inspection Applications

Supplied System SoftwareThesuppliedHRMAsoftwareprogram,usedtoconfigureeachSystemcontrolmodule,mayberunonanyPC-compatiblecomputerrunningWindows®XP, Vista, or 7..Themenu-drivenprogramwalkstheuserthroughthemanyscanningandoutputoptions.Afterthedesiredoptionsareselected,theusercansavethecombinationofselectionsinaParameterSetupFile(PSF),andstoreitinthecontrolmodule’snon-volatilememory.AnynumberofPSFsmaybestoredinthesystemconfigurationcomputerandrecalledasneeded.

Thesoftwarealsoprovidesalignmentanddiagnosticsroutines.AnAlignmentscreendisplaystheindividualstatusofeachbeaminthelightscreen,aswellasthetotalnumberofbeamsintheSystem,andtotalsofbeamsblocked,madeandblanked.Built-insystemdiagnosticscanbeusedtoassessemitterandreceiverhardwareerrors.

1.3 Typical Applications

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Sticky Note


P/N64118rev.B

Specifications


Environmental Rating

Minimum Object Sensitivity 2.5mm(0.1")

NEMA4,13(IP65)

Sensor Scan Time 1.8millisecondsto58.4milliseconds,dependingonscanningmethodandsensorlength;seeSection5.3.3fordetailedinformation

Power Requirements 12Vdc±2%,suppliedbycontroller

Status Indicators Emitter: RedLEDlightstoindicateproperemitteroperationReceiver: Greenindicatessensorsaligned Yellowindicatesmarginalalignmentofoneormorebeams Redindicatessensorsmisalignedoroneormorebeam(s)blocked

Connections Sensorsconnecttocontrollerusingtwo5-conductorquick-disconnectcables(oneeachforemitterandreceiver),orderedseparately.Seepage5foravailablelengths.UseonlyBannercables,whichincorporatea“twistedpair”fornoiseimmunity.Cablesmeasure8.1mm(0.32")indiameterandareshieldedandPVC-jacketed.Conductorsare20gauge(0.9mm).Emitterandreceivercablesmaynotexceed75m(250')long,each.

Construction Aluminum,withblackanodizedfinish;acryliclenscover

Operating Conditions Temperature:0°to+50°C(+32°to122°F)Maximum relative humidity:95%at50°C(non-condensing)

Emitter/Receiver Range 380mmto1.8m(15"to6')

2. Specifications

2.1 Emitter and Receiver Specifications

Certifications


P/N64118rev.B

10.2 mm(0.40")

L3

38.1 mmSquare(1.50")

53.8 mm(2.12")

2.5 mm(0.10")

18.3 mm(0.72")

47.2 mm(1.86")

L1

71 mm(2.8")

R13 mm (0.5")Minimum Bend

L2

Figure 2-1. Emitter and receiver dimensions

With mounting bracket flanges “in”With mounting bracket flanges “out”

Emitter/Receiver Model

Housing Length Distance Between Bracket Holes

MAHE6AEmitterMAHR6A Receiver 236mm(9.3") 268mm(10.5")

MAHE13A EmitterMAHR13A Receiver 399mm(15.7") 430mm(16.9")

MAHE19A EmitterMAHR19A Receiver 561mm(22.1")

MAHE26A EmitterMAHR26AReceiver 724mm(28.5") 756mm(29.7")

MAHE32A EmitterMAHR32AReceiver 887mm(34.9") 918mm(36.2")

MAHE38AEmitterMAHR38A Receiver 1049mm(41.3")

MAHE45AEmitterMAHR45AReceiver 1215mm(47.8") 1246mm(49.1")



MAHE64AEmitterMAHR64AReceiver 1703mm(67.0") 1734mm(68.3") 1677mm(66.0")

1515mm(59.6")

1189mm(46.8")

1024mm(40.3")

861mm(33.9")

699mm(27.5")

536mm(21.1")

373mm(14.7")

211mm(8.3")


MAHE77AEmitterMAHR77AReceiver 2028mm(79.8") 2060mm(81.1") 2003mm(78.8")

1840mm(72.4")

L1 L2 L3

593mm(23.3")

1081mm(42.6")

1352mm(53.2")

Specifications


P/N64118rev.B

Specifications


Status Indicators

Power Requirements [email protected](typical:0.5A@16Vdc)

Output 1 (red): LightstoindicateDiscreteOutput#1isactiveAlarm (red): LightstoindicateDiscreteOutput#2isactiveGate (red): LightstoindicateGATEinputisactiveAlign (green): LightstoindicateemitterandreceiverarealignedDiagnostics indicator: (Keyoncontrollersidelabel)IdentifiesSystemerrorsandstatus

Inputs Sensor input: Emitterandreceiverwireinparalleltofiveterminals.Gate input: Opticallyisolated,requires10to30Vdc(7.5kΩimpedance)forgatesignalRemote alignment input: Opticallyisolated,requires10to30Vdc(7.5kΩimpedance)foralignment

sequencesignal

Discrete (Switched) Outputs NPN outputs:OpencollectorNPNtransistorratedat30Vdcmax.,150mAmax.PNP outputs: OpencollectorPNPtransistorratedat30Vdcmax.,150mAmax.All discrete outputs: OFF-state leakage current: <10µA@30Vdc ON-state saturation voltage: <1V@10mAand<1.5V@150mA

Serial Data Outputs RS-232orRS-485interface.(Upto15controlmodulesmaybegivenuniqueaddressesononeRS-485partyline.)ASCIIorbinarydataformat9600,19.2K,or38.4Kbaudrate8databits,1stopbit,andeven,odd,ornoparity

Analog Outputs Voltage-sourcing outputs:0to10Vdc(25mAcurrentlimit)Current-sinking outputs:4to20mA(16to30Vdcinput)Resolution: Span/NumberofsensingchannelsLinearity:0.1%offullscaleTemperature variation:0.01%offullscaleper°C

System Programming ViaRS-232interfacetoPC-compatiblecomputerrunningWindows®XP, Vista, or 7andusingsoftwaresuppliedwitheachcontrolmodule.

Construction Polycarbonatehousing;mountstoflatsurfaceordirectlyonto35-mmDINrail

Environmental Rating Control Module:NEMA1,IECIP20Emitter/Receiver:NEMA4,13;IECIP65

Output Configuration MAHCVP-1:TwoPNPdiscrete(switched),two0-10VvoltagesourcingMAHCVN-1: TwoNPNdiscrete(switched),two0-10VvoltagesourcingMAHCIP-1:TwoPNPdiscrete(switched),two4-20mAcurrentsinkingMAHCIN-1:TwoNPNdiscrete(switched),two4-20mAcurrentsinking

2.2 Control Module Specifications

Operating Conditions Temperature:0°to+50°C(+32°to122°F)Maximum relative humidity:95%@50°C(non-condensing)

Certifications

psanchez

Sticky Note



P/N64118rev.B

81.0 mm(3.19")

115.0 mm(4.53")

106.0 mm(4.17")

35.0 mm(1.38")

DIN mounting slot

Slot for M3.5 screws (2)5.5 mm(0.22")

69.0 mm(2.72 ")

5.0 mm(0.20")

96.0 mm(3.78")

Figure 2-2. Control module dimensions

Specifications


P/N64118rev.B

Installation and Mechanical Alignment

12Banner Engineering Corp. •Minneapolis,U.S.A.

www.bannerengineering.com•Tel:763.544.3164

3. Installation and Mechanical Alignment

3.1 Emitter and Receiver Mounting

BannerMINI-ARRAYemittersandreceiversaresmall,lightweight,andeasytohandleduringmounting.Themountingbrackets(supplied)allow±30°rotation.

Fromacommonpointofreference,makemeasurementstolocatetheemitterandreceiverinthesameplanewiththeirmidpointsdirectlyoppositeeachother.MounttheemitterandreceiverbracketsusingthevibrationisolatorsandM4Kepsnuts(allsupplied).SeeFigure3-1.StandardM4or#8-32boltsmaybesubstituted(andthevibrationisolatorseliminated)insituationswheretheemitterandreceiverarenotsubjectedtoshockorvibrationforces.Whiletheinternalcircuitsoftheemitterandreceiverareabletowithstandheavyimpulseforces,thevibrationisolatorsdampenimpulseforcesandpreventpossibledamageduetoresonantvibrationoftheemitterorreceiverassembly.

Figure 3-1. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting hardware

MountingSurface

M4 KepsNut (8)

M4 x 10 mm Slotted Hex Head with Com pres sion

Washer (2)

MountingBracket

Emitter orreceiver

Anti-Vibration Mount (4)

Mounting Bracket

Washer

Nut

Studs: M4 x 0.7 9.5 mm (0.38") long


P/N64118rev.B

NON-QD EndQD End

Min. R.

Full R (4)

4.8 mm (2)(0.19")

38.1 mm(1.50")

6.4 mm R(0.25")

44.5 mm(1.75")

6.4 mm(0.25")

57.2 mm(2.25")

3.8 mm(0.15")

10.2 mm (2)(0.40")

ø30.5 mm(1.20")

34.8 mm(1.37")

11.9 mm(0.47")

Slots have clearancefor M4 bolts (supplied)

and allow ±30° rotation

ø13.2 mm(0.52")

ø6.8 mm (2)(0.27")

3.0 mm(0.12")

24.6 mm(0.97")

53.8 mm(2.12")

Material: Cold Rolled SteelFinish: Black, Zinc Plated

Chromate Dip

Figure 3-2. A-GAGE High-Resolution MINI-ARRAY emitter and receiver mounting bracket dimensions



Mounttheemitterandreceiverintheirbracketsandpositiontheredlensesofthetwounitsdirectlyfacingeachother.Theconnectorendsofbothsensorsmustpointinthesamedirection.Measurefromoneormorereferenceplanes(e.g.thebuildingfloor)tothesamepoint(s)ontheemitterandreceivertoverifytheirmechanicalalignment.Ifthesensorsarepositionedexactlyverticalorhorizontaltothefloor,acarpenter’slevelisusefulforcheckingalignment.Astraightedgeorastringextendedbetweenthesensorsalsohelpswithpositioning.Alsocheck“byeye”forline-of-sightalignment.Makeanynecessaryfinalmechanicaladjustments,andhand-tightenthebrackethardware.SeeSection6forinformationonalignmentindicatorsandSection5forinformationontheuseofthealignmentsoftwarewhichissuppliedwiththecontroller.

3.2 Control Module Mounting

ThecontrolmodulemustbeinstalledinsideanenclosurewhichhasaNEMA(orIEC)ratingsuitablefortheoperatingenvironment.

MountingdimensionsforthecontrollerareshowninFigure2-2,onpage11.ThecontrolmoduleissuppliedwithM3.5hardwarefordirectmountingtoasurface,orthemodulemaybemountedontostandard35mmDINrail.

P/N64118rev.B



POWER

1

+ –

+ –

16-30V dc 1 A max

10-30V dcGATE

SIGNAL

+30V dc max

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

BROW

N

BLUE

DRAI

N (B

ARE)

BLAC

K

WHI

TE

DISCRETEOUTPUT#1

150 mAmax

EMITTER andRECEIVER CABLES

TX TX

DISCRETEOUTPUT#2 (ALARM)

+ –10-30V dc

ALIGN

RS-485

+30V dc max

150 mAmax

25 mAmax

0-10VANALOG

OUTPUT #2

25 mAmax

0-10VANALOG

OUTPUT #1

Figure 3-3. MAHCVN-1 hookup

POWER1

+ –

+ –

16-30V dc1 A max

10-30V dcGATE

SIGNAL

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

BROW

N

BLUE

DRAI

N (B

ARE)

BLAC

K

WHI

TE

DISCRETEOUTPUT#1


TX TX

+ –10-30V dc

ALIGN

RS-485

150 mAmax

25 mAmax

0-10VANALOG

OUTPUT #2

25 mAmax

0-10VANALOG

OUTPUT #1


150 mAmax

Figure 3-4. MAHCVP-1 hookup

+30V dc max

POWER1

+ –

+ –

16-30V dc1 A max

10-30V dcGATE

SIGNAL

+30V dc

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

BROW

N

BLUE

DRAI

N (B

ARE)

BLAC

K

WHI

TE



DISCRETEOUTPUT#1

+ –10-30V dc

ALIGN

Load

+16-30V

4-20 mAANALOGOUTPUT#2

4-20 mAANALOGOUTPUT#1

+16-30V

150 mAmax

150 mAmax

TX TXRS-485

Load

Figure 3-5. MAHCIN-1 hookup

+16 – 30V dc+16 – 30V dc

POWER1

+ –

+ –

16-30V dc 1 A max

10-30V dcGATE

SIGNAL

4-20 mAANALOGOUTPUT #1

4-20 mAANALOG

OUTPUT #2

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

BROW

N

BLUE

DRAI

N (B

ARE)

BLAC

K

WHI

TE



+ –10-30V dc

ALIGN

Load Load

150 mAmax

DISCRETEOUTPUT#1

150 mAmax

TX TXRS-485

Figure 3-6. MAHCIP-1 hookup

3.3 Hookups

RefertoFigures3-4,3-5,3-6,and3-7fortheappropriatehookupinformation.


P/N64118rev.B

2 - TX3 - RX5 - COM

RS-232

5 3 2


Serial Communication RS-232:AllA-GAGEHigh-ResolutionMINI-ARRAYSystemsmaycommunicatewitha

hostcomputerorcontrollerviaRS-232orRS-485serialprotocol.SeeSection5.3.1forselectablecommunicationsparameters.PrepareanRS-232cableusingamaleDB-9connectorwithconnectionsasshowninFigure3-8.

NOTE:DONOTusea“nullmodem”RS-232cable

RS-485: RS-485serialportislocatedatterminals#18(TX)and#19(TX).

DB-9 Pin # Function

2 Transmit(TX)

3 Receive(RX)

5 Ground(GND)

3.3.1 Emitter and Receiver Hookups

Emittersandreceiversconnecttogetherinparalleltoterminals#4through#8ofthecontrolmodule(identicalforallcontrolmodulemodels).SeeFigures3-3,3-4,3-5,and3-6forwirecolorinformation.

3.3.2 Inputs

System Power: Connectasourceof16to30Vdc,ratedat1amporgreater,tocontrolmoduleterminals#1(+)and#2(-).Connectagoodearthgroundtoterminal#3toprovideelectricalandRFnoiseimmunitytotheSystem.

NOTE:Removepowerbeforemakingotherconnectionstothecontroller.

Gate Signal: Asourceof10to30Vdcswitchedtoterminals#12(+)and#13(-)providesagatinginput(ifrequired).Thegatingvoltagetypicallyisswitchedbytheopen-collectoroutputtransistorofadcsensingdevice.ThegatesignalcontrolsscanningwhenoneoffourGateoptionsisselectedintheControlModeSelectionmenuofthePSFconfigurationroutine(seeSection5.3.2).

Align: Asourceof10to30Vdcswitchedtoterminals#14(+)and#15(-)providesaremotemeansofrunningtheautomaticalignmentandblankingroutines.TheswitchsequenceisidenticaltotheproceduredescribedinSection5.2.1fortheAlignment

switchonthefrontofthecontrolmodule.

Control ModuleAnalog Outputs

(Terminals #10 and 16)Discrete Outputs*

(Terminals #9 and 20)

MAHCVN-1Figure3-3

0to10VSourcing15mAmax.

NPNopen-collector30Vdcmax.150mAmax.

MAHCVP-1Figure3-4

0to10VSourcing15mAmax.

PNPopen-collector30Vdcmax.

MAHCIN-1Figure3-5

4to20mASinking

16to30Vdc

NPNopen-collector30Vdcmax.150mAmax.

MAHCIP-1Figure3-6

4to20mASinking

16to30Vdc

PNPopen-collector30Vdcmax.150mAmax.

*NOTE:DiscreteOutput#2islabeled“Alarm”onthecontrolmodule.Figure 3-8. DB-9 connections between the control module and the PC

Trim braided shield flushwith cable

Trim foil shield flushwith cable

Uninsulateddrain wire

Figure 3-7. Emitter and receiver cable preparation


NOTE:The“drainwire”istheuninsulatedstrandedwirewhichrunsbetweenthebraidedshieldandthefoilshield.Thefoilshieldandthebraidedshieldshouldberemovedatthepointwherethewiresexitthecable.

3.3.3 Outputs

16Banner Engineering Corp. • Minneapolis, U.S.A.www.bannerengineering.com • Tel: 763.544.3164

P/N 64118 rev. B

Software Installation

16Banner Engineering Corp. • Minneapolis, U.S.A.www.bannerengineering.com • Tel: 763.544.3164

4. Software InstallationThe High-Resolution MINI-ARRAY software CD includes an installation routine that quickly and easily loads the MINI-ARRAY configuration program into your computer. The High-Resolution MINI-ARRAY configuration program requires approximately 50 MB of hard disk space. Install as follows:

1. Use the Parameter Setup Software CD included with the controller, or download (www.bannerengineering.com) as required.

2. Insert the Software CD into the CD drive. If the program does not auto-start, browse to your CD drive, click Setup.exe, then select START, then select RUN.

2. The Welcome dialog box will appear. Select Next, and follow the prompts in the dialog boxes as they appear.

4. The installation program then decompresses the files. A status dialog box monitors the progress of the installation.

5. An Installation Completed dialog box appears. Select OK. Reboot your computer for the changes to take effect.

After the software is installed, a MINI-ARRAY shortcut icon is placed on your desktop. Double-click on the MINI-ARRAY icon to launch the program, then follow the configuration and setup procedures described in Section 5 of the primary manual.

Figure 4-1. MINI-ARRAY software installation: dialog boxes


P/N64118rev.B

Control Module Configuration


Figure 5-1. Options menu, serial port selection

Figure 5-2. MINI-ARRAY menu

Figure 5-3. Screen showing the result of a completed Ping routine

5. Control Module Configuration

TheA-GAGEHigh-ResolutionMINI-ARRAYcontrolmoduleiseasilyconfiguredusingaWindows®menu-styleroutine;theconfigurationroutinerequirestheBanner-suppliedHRMAsoftwareandaPC-compatiblecomputer(running Windows® XP, Vista, or 7)AserialdataconnectionismadebetweenthecomputerandtheDB9connectoronthecontrolmodule.

5.1 Communications Setup

Afterinstallingthesoftware,attachtheserialcommunicationcablebetweenthecontrolmoduleandthePC.(NOTE:IfanRS-232interfaceisused,onlyonecontrolmoduleisallowedonthelineatanyonetime.)Theminimumconnectionstothecontrolmodule’sDB-9connectorareshowninFigure3-8.

LaunchtheHigh-ResolutionMINI-ARRAYprogramandconfiguretheserialcommunicationsportofthePC.SelecttheOptionsmenufromtheHigh-ResolutionMINI-ARRAYmainmenu(seeFigure5-1).TheprogramsupportsserialcommunicationviatheCOM1-COM20.portofthecomputer.Highlightthedesiredserialporttoselectit(a“bullet”willappearnexttotheselectedoption),thenselectSave Settings on Exittostoretheserialportselection,ifitisnotalreadyON(a“bullet”willappearnexttotheoption,ifitisON).

Parityisselectedherealso:Even,OddorNone.

5.1.1 Ping Routine

ThePingroutinemustbeperformedduringSystemconfiguration,andbeforeanyDiagnostic,Alignment,orEditroutine.Theroutinepollsallcontrolmodulesonthecommunicationsline(one,inthecaseofthestandardRS-232line,orupto15modules,onanRS-485circuit).Itthenisusedtoselectanindividualcontrolmoduleforconfigurationoralignment.

Ifneeded,applypowertotheSystemcontrolmoduleandallowtheSystemtocompleteitspower-uproutine.PressF5oraccesstheMINI-ARRAYmenuandselectPingtoperformthePingroutine.AllconnectedcontrolmoduleswillthenidentifythemselveswithanIDvalueandbaudrate;theroutinetakesapproximately15to20seconds.AfterthePingisperformed,allvalidcontrolmoduleIDvalueswillappearinachartonthescreen,undertheirappropriatebaudrates(seeFigure5-3).Controlmodulesareidentifiedinthechartas‘X.’PointtoavalidIDwiththemousepointerandclicktoselectacontrolmodule.SystemDiagnostics,Alignment,orEditroutinesmaynowbeperformedfortheselectedcontrolmodule.

P/N64118rev.B



5.1.2 Factory Settings

Ofthe15availablecontrolmoduleIDvalues(‘A’through‘O’),thefactorysoftwaresettingisA.Selectablecommunicationbaudratesare9600,19200,and38400;thefactorysettingis9600.Seesection5.3.1forinformationonchangingthesesettings.

5.2 System Alignment

Theemitter/receiverpairshaveawidefieldofviewandareeasytoalign.Therecommendeddistancebetweentheemitterandreceiverrangesfrom15"to72".(Shortersensorseparationcanbeachieved;pleaseconsultfactoryfordetails.)TheAlignmentprocessshouldbeperformedatSysteminstallationandrepeatedeverytimeoneorbothofthesensorsismoved.AlignmentoftheSystemcanbespecifiedautomaticallyusingeithertheAlignmentroutineoftheconfigurationsoftwareortheAlignmentswitchonthecontrolmodule’sfrontpanel.

TheSystemalsomaybealignedremotely,usingpins14and15ontheterminalblock.Apply10to30Vdcpowertothepins(seepage14)toapproximatethepush-buttonprocedure.(Forexample,applyinputsignalfor3secondstoaccessAlignmentmode.)

Makesurethesensorshavebeenwiredasshowninsection3.3.Applypowertothecontrolmoduleviaterminals#1and#2(16to30Vdc).TheDiagnosticsIndicatorwillshowthesensorsgoingthoughapower-uptest:firstthereceiver,thentheemitter.AfterthesensorshavebeentestedandtheSystemisreadyforservice,theDiagnosticsIndicatorwillshow‘—’or‘—.’;seeFigure5-4.

5.2.1 Push-button Alignment Routine

Atinstallationorwhenevertheemitterand/orreceiverismoved,theSystemshouldbere-aligned.PresstheAlignmentswitchonthecontrolmodulefrontpanelfor3seconds,afterwhichtimetheletter‘A’willappearontheDiagnosticsIndicator;theSystemis“learningaclearcondition.”Rotatethesensorsasrequired(butdonotchangethedistancebetweenthem).WhenthegreenAlignmentLEDisdisplayedonthecontrolmoduleandreceiver,thesensorsareadequatelyaligned.ToleaveAlignmentmode,againpresstheAlignmentswitchfor3seconds.

Duringthealignmentprocedure,thesystempollseachreceiverchanneltomeasureexcessgainandperformsacoarsegainadjustment.Whenthesystemexitsthealignmentprocedure,eachchannel’ssignalstrengthisstoredinnon-volatilememory.Thesystemisnowreadyforoperationanddoesnotrequirere-alignmentunlesstheemitterorreceiverismoved.

Figure 5-4. Diagnostics Indicator showing a clear condition


ALIGNMENTSWITCH

POWER

POWER


2 - TX3 - RX5 - COM

RS-232

MAHCN-1

OUTP

UT

ALAR

M

GATE

ALIG

N

1

+ –

+ –

16-30V dc1A MAX

10-30VDCGATE

30V150mA MAXEMTR RCVR

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

NC NC NC+12V COM DRN T/R T/R

BR BU BK WHOUTPUT#1

TX TX

30V(MAX)150mA MAX

ALARM

+ –10-30VDC

ALIGN

RS-485


ALIGNMENTSWITCH

POWER

POWER


2 - TX3 - RX5 - COM

RS-232

MAHCN-1

OUTP

UT

ALAR

M

GATE

ALIG

N

1

+ –

+ –

16-30V dc1A MAX

10-30VDCGATE

30V150mA MAXEMTR RCVR

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1

NC NC NC+12V COM DRN T/R T/R

BR BU BK WHOUTPUT#1

TX TX

30V(MAX)150mA MAX

ALARM

+ –10-30VDC

ALIGN

RS-485

DenotesBlanking

With Blanking OFF

With Blanking ON


P/N64118rev.B

5.2.2 Software Alignment Routine

ThegreenLEDindicatoronthereceiverandalsoonthecontrolmodulecontinuouslydisplaysAlignmentstatus.Whenallunblankedbeamsareclear,thegreenAlignmentindicatorswillbeON.Tobetterunderstandblocked,clearandblankedbeams,launchtheAlignmentroutine(pressF8orselectAlignmentundertheMINI-ARRAYmenu).Thescreenwillshowthestateofallofthebeamchannels,groupedintosetsof16.

KeyinformationprovidedontheAlignmentscreenisthesensorsize,plusthenumberofbeamsblocked,made,andblanked.Thesensorsizeisgiventhetitleof“total”;thisreferstothetotalnumberofbeamchannelsinthearray.Thenumberofbeamsblockedisarunningtotalofblockedbeams,excludinganyblankedbeams.The“made”valueisacountofunblockedbeams.The“blankedvalue”isacountofthenumberofbeamchannelsthatareblanked(channelsthatareignoredformeasurementmodeapplications;seesection5.2.3).

TheAlignmentscreenprovidesthefollowingfunctions:Start,Stop,Step,ClearBlankingFields,RestoreControlmoduleSettings,AutoBlanking,AbortAutoBlanking,SavetoFile,ReadFromFile,Cancel,OK,andEdit.Toaccessanyofthesesub-routines,firstpressStop,thentheselectedoption.

Startcommandcausesthecontrolmoduletocontinuouslyscanandreport“AllChannelData.”Thisdataisusedtoupdatethestateofeachbeamchannel.

Stopcommandcausesthecontrolmoduletostopscanning.

Stepcommandproducesonescanandthenstopsuntilanothercommandisissued.

Clear Blanking Fieldscommandisaquickwaytoremoveblankingspecifications.

Restore Control Module SettingswillrecalltheblankingspecificationsineffectpriortoAlignment/Blankingbeingentered.

Auto Blankingcommandisusedtoscananddeterminewhichbeamsareblocked;blockedbeamsautomaticallybecomeblankedbeams.TheAutoBlankingvaluescanthenbeAcceptedorAborted.

Editisusedtocontroltheblankingspecificationsofanychannelmanually.Thisisusefulforaddinganynumberofblankedbeamchannelsaboveand/orbelowablankedobjecttoallowforvibrationorothermovementoftheobjecttobeignored.

BlankingspecificationscanbesavedandreadfromacomputerfileusingtheSave To FileandRead From Filecommands.

Figure 5-5. Alignment screen





5.2.3 Blanking

Ifamachinefixtureorotherequipmentwillcontinuouslyblockoneormorebeams,theaffectedbeamchannelsmaybeblanked.TheBlankingoptioncausesthecontrolmoduletoignorethestatusofblankedbeamsformeasurementmodecalculations.Forexample,ifamachinefixtureblocksoneormorebeamsduringSystemoperation,theoutputdatawillbeincorrect;ifbeamsblockedbythefixtureareblanked,theoutputdatawillbecorrect.Blankingmaybeconfiguredusingthepush-buttonAlignmentswitchonthecontrolmodule,orbyusingthesystemsoftwareandacomputer.

Push-Button Blanking Setup Routine To specify blanking using the control module’s Alignment switch,(seeFigure5.4)positiontheobjectorparttobeignoredinthepathofthebeamsbeforebeginningtheAlignmentroutine.PresstheAlignmentswitchfor3seconds;theDiagnosticsIndicatorwillshowtheletter‘A’.PresstheAlignmentswitchagain,butthistimeonlymomentarily(about0.5secondsmax.).TheDiagnosticsIndicatorwillshowtheletter‘b’toindicateitisreadyto“learn”theblankingpattern.Again,momentarilypresstheAlignmentswitchtosettheblankingfields.Boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshow‘A.’(theperiodfollowingthe‘A’indicatesthatblankingisinuse).Thebeamsblockedduringtheroutinearenowblanked.ToreturntoRunmode,againpresstheAlignmentswitchfor3seconds.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing‘—.’(seeFigure5-4).

System Software Blanking Setup Routine To specify blanking using the System software,theprocedureissimilar.Positiontheobjecttobeblankedinthepathofthebeams(thiscanbedoneatanytimebeforebeginningtheblankingroutine).PerformthePingroutinetoselectthepropercontrolmodule,thenpressF8orselecttheAlignmentoptionfromtheMINI-ARRAYmenu.Fromthescreenmenu(Figure5-6),selectStop;theDiagnosticsIndicatoronthecontrolmodulewillshowtheletter‘A’.SelectAuto Blanking (Figure5.7);theDiagnosticsIndicatorwillshowtheletter‘b’.SelectAccept Auto Blanking;boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshow‘A.’(theperiodfollowingthe‘A’indicatesthatblankingisinuse).Thebeamsblockedduringtheroutinearenowblankedandappearastheletter‘B’onthegridinsteadof‘0’;ifyouwishtoblankadditionalbeams,usethe‘Edit’keytomanuallysetadditionalblanking(seenextpage).ToleaveAlignmentmode,select‘OK’.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing‘—.’(seeFigure5-4).

Scanning Mode Limitations for Blanking:AllblankingfeaturesareavailablewithContinuousScanmode.Forsingle-anddouble-edgescan,blankingislimitedtofourblankingfields.Otherblankingfeaturesareignored.

Figure 5-6. Alignment screen, showing beams #1-11 blocked

Figure 5-7. Alignment screen, showing beams #1-11 blanked


P/N64118rev.B



To accommodate parts or components that will move through the array,blankingmaybemanuallyadjustedforoneormoreindividualbeamchannels.AfterusingtheSystemsoftwaretospecifyblanking,select‘Edit’fromtheAlignmentscreen;theDiagnosticsIndicatorwillcontinuetoshowtheletter‘b’andagridwillappearonthecomputerscreen(Figure5-8).Thebeamsarenumberedfromthesensors’cabledends,withthebeamclosesttothecablebeingbeam#1.Tosettheblankingfields,‘click’eachgridboxrepresentingabeamyouwishtoblank.

Clickingagainonablankedbeamchannelwillremovetheblankingspecification.Rowsofchannelscanbeselectedorclearedoftheblankingspecificationbyplacingthecursordirectlytotheleftoftherowtobeselectedandclickingthemouse;therowshouldbehighlighted.SelecttheBlank Selected(toaccepttheblankingstatus)orClear Selected(torejecttheblankingstatus)option.ToleaveAlignmentmode,select‘OK’.Boththecontrolmoduleandthereceiverwillindicateaclearcondition(greenAlignindicatorON)andtheDiagnosticsIndicatorwillshow‘A.’.WhentheSystemisreadyforoperationandconfiguredforbeamstobeblanked,theperiodontheDiagnosticsIndicatorwillremainlit,showing‘—.’(seeFigure5-4).

Figure 5-8. Edit channel blank state screen, showing beam #22 and beams #35-42 blanked; beams #65-80 are highlighted, ready to be selected for blanking

5.3 Programming Control Module Response

TheParameterSetupFile(PSF)Configurationroutine(seeFigure5-9)isusedtoconfigurethecontrolmoduleforaspecificapplication.AccessthePSFConfigurationscreen(afterperformingthePingroutinetoselectacontrolmodule,section5.1.1)byselectingEdit PSF (F4)fromtheMINI-ARRAYmenu.TheEditPSFprocessmayalsobeperformedwithnocontrolmoduleselected,toconfigureandsaveaPSFformultiplecontrolmodules.Insuchacase,somefieldsonthePSFConfigurationscreenwillnotbeaccessible.

Theprocessofconfiguringthecontrolmoduleinvolvesselectingamongoptionsforeachoftheparameterslistedinthissection,includingserialcommunication,controlmode,scanningmethod,scananalysismode,serialtransmission,andanalog/discreteoutputs.Theresultingcombinationofoptionscausesthecontrolmoduletoreactasrequiredfortheapplication,tochangesinthelightscreen.

TheconfigurationprocessproducesaParameterSetupFile(PSF).PSFfilesmaybesavedandretrievedascomputerfilesviatheFile Save PSFandFile Retrieve PSFcommands(seesection5.4.5).Onceconfigured,aPSFmaybesenttothecontrolmoduleviatheSend PSFcommand.Likewise,thePSFcurrentlyloadedintothecontrolmodulemaybedisplayedbyusingtheUpload PSFcommand.

P/N64118rev.B



Figure 5-9. Use the PSF Configuration screen to program each control module individually

Serial TransmissionSpecifiesthetypeofdatatransmittedfromthecontrolmoduletoitshostaftereachscan.Measurement Mode Result:DatatransmittedwillreflecttheAnalysisModeselections.All Mode:Transmitsalldata.Max. Meas. Mode: Sendsonlythelargestmeasurementineachmeasuringevent,todecreasetransmissionsizeandspeedresponse.Choosetosendwhenthearrayisclearorsendatthehost’srequest.Transmission Type: ASCIIorBinary,definestheformatinwhichthedatawillbesent.Serial Options:SuppressClearDataorSuppressHeadertodecreasetransmissionsizeandspeedresponse.

Analysis (Measurement)Mode Selection

Choosethemeasurementoptionthatbesttellsyouthesizeand/orposition

ofobjectsastheyrelatetothearray.

Control Mode SelectionContinuous Mode:Thecontrol

moduleconstantlypollsthearrayforstatus.

Host Mode:Thecontrolmodulepollsthearrayforstatuswhenpromptedbyahostcontroller.

Gate Mode: Thecontrolmodulepollsthearrayforstatuswhenpromptedbyaninputfroma

Gatesensor.

Scanning MethodStraight scanpollseachbeam

sequentiallytodeterminethetargetobject’soverallsize.Thisisthemostaccurateandprecisemeasurement,butalsothemosttime-consuming.

Single Edge scanrequiresthetargetobjecttoblockbeam1(closesttothesensors’cabledends),thenconductsatime-savingbinarysearchto“hunt”forthetarget’s

overallheight(onevariableedge).

Double Edge scanconductsatime-savingsearchoftheentirearrayto“hunt”forthetarget’s

overallwidth(twovariableedges).

Set Point and Hysteresis SelectionAssignsthesetpointtodeterminewherewithinthearraytheoutput(s)willrespondandhysteresisvaluestosmoothoutputresponse.

Trigger/Trigger Channel NumberMaybeusedtotrigger(orgate)thescansequenceofanotherA-GAGE High-Resolution MINI-ARRAYcontroller;instraightscanningmode,itdefineswhenduringeachscandiscreteOutput#2willchangestate.

Scan #: (1-9)Analogoutputsareupdatedwithanaveragevalueofthedatareceivedduringtheselectednumberofscans;discreteoutputsrespondonlyifthereceiveddataisidenticalforalloftheselectednumberofconsecutivescans.

Analog and DiscreteOutput Assignment

Assignsananalysis(measurement)mode

toeachoutput.Alarm:CausesthecontrolmoduletoturnondiscreteOutput#2whenevertheSystemdetectsasensingerrororiftheopticalsignalbecomesmarginal.

Selected Controller Identifiesthespecificcontrolmodulebeing

configured.

Serial CommunicationChangestheidentificationandbaudrateofthecontrollerbeingconfigured.

Zero Value ZeroValueisusedtospecifytheanalogoutputwhenthemeasurementmodevalueiszero.TheusercanspecifyavalueofLAST,NULL,orSPAN.

LAST: Outputholdsthelastnon-zerovaluebeforethelightscreenbecameclear.

NULL: Providestheminimumvalue.

SPAN: Providesthemaximumvalue.


P/N64118rev.B

5.3.1 Selected Controller and Serial Communication

TheSelectedControllerboxdisplaysinformationaboutthecontrolmodulebeingconfigured.TwoofthesesettingsmaybechangedintheSerialCommunicationbox.ThesettingsselectedanddisplayedintheseboxesarethoseusedtoidentifythecontrolmoduleduringthePingroutine(section5.1.1).

Controller ID(assignedaletter,‘A’through‘O’)isusedtoidentifyeachindividualcontrolmodulewhenmultiplediscrete-outputcontrolmodules(upto15)areconnectedononeEIA-485“partyline.”NOTE:AnalogoutputcontrolmodulesdonotofferRS-485communication;chooseanyIDletter(‘A’through‘O’)whenprogrammingananalog-outputcontrolmodule.

Baud Rateisthedatacommunicationratebetweenthecontrolmoduleandthecomputerusedforconfigurationandalsotheprocesscontroller.Choosefromthreevalues:9600, 19200,and38400.

Parity: SelectOdd,Even,orNone.AllcontrollersononeEIA-485partylineshouldhavethesameparitysettings.

5.3.2 Control Mode Selection

Thecontrolmodedeterminesthemethodusedtocontrolscanningofthelightscreenarray(seeFigure5-11).Choosefromthreemaincontrolmodes:

• ContinuousScanmode,• SerialHostCommandmode,and• Gatemode(whichitselfhasfouroptions)

In Continuous Scan Mode,thecontrolmodulebeginsanewscanassoonasitupdatestheoutputsfromthepreviousscan.Thisisthefastestscancontrolmethod;itisusedinmostanalogoutputapplicationsandwhenevercontinuousupdatingoftheoutputsisacceptable.

Host ModeallowsthecontrolmoduletocommunicatewithahostcomputerorcontrolmoduleviaRS-232(allmodels)orRS-485(discrete-outputmodelsonly)serialprotocol.ThehostdirectsthecontrolmoduletoscanondemandandreceivestheoutputdatafromthecontrolmoduleinbinaryorASCIIform.Baudratesof9600,19200,and38400areselectableintheSerialcommunicationsmenu(section5.3.1).(SeeAppendixAformoreinformationonHostmodedataformat.)

Gate ModeactivatesanopticallyisolatedexternalGateinputbetweenterminals12(+)and13(-)ofthecontrolmodule.TheGateinputhasimpedanceof7.5kΩandacceptsa10to30Vdcsignal.AdcdevicesuchasaphotoelectricsensororopticalencodertypicallysuppliestheGateinput.Gateinputsignalsmustbegreaterthan150microsecondsinduration;thetimebetweensuccessiveGateinputsmustbegreaterthantheminimumscantimeforthelightscreenarray(seesection5.3.3forscantimeinformation).

Gatemodehasfouroptions:• Gate ON: thecontrolmodulewillscanaslongasthegateisactive.• Gate OFF: thecontrolmodulewillscanwheneverthegateisnotactive.• Gate ON/OFF: thecontrolmodulewillscanonceforeachgatetransitionfromONtoOFF.• Gate OFF/ON:thecontrolmodulewillscanonceforeachgatetransitionfromOFFtoON.

Figure 5-11. Control Mode selections (PSF Configuration screen)

Figure 5-10. Selected Controller and Serial Communication selections (PSF Configuration screen)



P/N64118rev.B



5.3.3 Scanning Method

Thecontrolmodulemaybeconfiguredforoneofthreescanningmethods(Figure5-12):• Straightscan• Single-Edgescan• Double-Edgescan

Straight Scanisthedefaultmodeinwhichallbeamsarescannedinsequencefromthebottomend(cableend)tothetopendofthearray.Thisscanningmethodrequiresthelongestscantimesandprovidesthesmallestobjectdetectionsize(2.5mm,0.1"diameter).

Single-Edge Scanisusedtomeasuretheheightofasingleobject.Agoodapplicationforthisscanningmethodisboxheightmeasurement.ForSingle-EdgeScan,theSystemalwaysactivatesthefirstbeamchannel(nearestthecableend,or“bottom”).Ifthefirstbeamisblocked,thesensorwillperformabinarysearchtohuntforthelastbeamblocked.Single-EdgeScanworksasfollows:

1. Thereceiverscansonlythebottombeamuntilthatbeamisblocked.

2. Whenthebottombeamisblocked,thesensorlookstoseewhetherthemiddlebeamisblockedormade(unblocked).

3. Ifthemiddlebeamismade(unblocked),thesensorchecksthebottomquarterbeam;ifthemiddlebeamisblocked,thesensorchecksthetopquarterbeam.(Thisiscalledabinarysearch;seeFigure5-13.)

4. Thisroutinecontinuesto“narrowthefield”untiltheedgeisfound.

Notethatthereceiveralwayschecksthebottombeamfirst,andonlyifthatbeamisblockeddoesthebinarysearchcontinue.Therefore,Single-EdgeScanwillnotworkininstanceswhereanitemthatdoesnotblockthefirstbeamistobemeasured.Single-EdgeScanisalsoineffectiveiftheobjectdoesnotpresentacontinuousblockedpattern.Inotherwords,Single-EdgeScanisusedforsingle,solidobjectsthatblockthefirstbeam.

Figure 5-12. Scanning Method selections (PSF Configuration screen)

DIAGNOSTICS

Error No.

Error Type

Error No.

Error Type

—�

System OK

4

Emitter Error

1

Align / blank

5

Serial Comm

2

Output Short

6

EEPROM

3

E / R Mismatch

7

CPU Error

4

Receiver Error

8

Null / Span

1POWER

2 - TX

3 - RX

5 - COM

ALIGNMENT

SWITCH

DIAGNOSTICS

INDICATOR

RS-232

MAHCN-1


23

45

67

89

1011

1213

1415

1617

1819

20

1

+

NC

NC10-30Vdc

GATE

NC

TXTX

+12V

BR

EMTR

RCVR

BU

BK

5 Wires

WH

30V

150mA MAX

OUTPUT#1

COMDRN

T/RT/R

16-30V dc

1A MAX

POWER2

34

56

78

910

1112

1314

1516

1718

1920

OUTP

UTAL

ARM

GATE AL

IGN

–�

+–�

F1

30V(MAX)

150mA MAX

ALARM

10-30Vdc

ALIGN

RS-485+

–�

High-ResolutionEmitter

MAHCN-1Control Module

High-ResolutionReceiver

Beam #1 of 64Blocked

Beam #48Clear

Beam #32Blocked

Beam #44Clear

Beam #40Blocked

Beam #42Blocked

Beam #43Blocked

Step #2Step #1 Step #3

Step #4 Step #5 Step #6 Step #7

Figure 5-13. Finding an edge using a binary search


P/N64118rev.B

Double-Edge Scanisusedtodetecttwoedgesofasingleobject,forexample,boxwidthmeasurements.Double-EdgeScanrequirestheselectionofastepsize:2,4,8,16or32beams.Thesensorusesthestepsto“skip”overbeams.Double-EdgeScanworksasfollows:

1. Thesensoractivatesbeam#1(thebeamclosesttothesensorcableend).

2. Thesensoractivatesthenextbeam,determinedbythestepsize.(Forexample,ifthestepsizeis2,beam#3isnext;ifthestepsizeis8,beam#9isnext.)

3. Aslongastheactivatedbeamisunblocked(or“made”),thesensorwillcontinuethesteppingroutineuntilablockedbeamisfound.

4. Whenablockedbeamisfound,abinarysearchisconductedtofindtheobject’s“bottomedge.”

5. Whenthebottomedgeisfound,thesensorbegins“stepping”againthroughthearrayuntilthesensorfindsthenextunblockedbeam.

6. Abinarysearchisagainperformedtofindthesecondedge.

Notethatthisscanningmethodsacrificesobjectdetectionsizeforspeed.SimilartoSingle-EdgeScan,Double-EdgeScanhassomerestrictions:theobjectshouldprovideasolidobstruction;thesizeoftheobjectwilldeterminethemaximumstepsize(Figure5-14).

Sensorresponsetimeisafunctionofsensorlengthandscanningmethod.TypicalscantimesareshowninFigure5-15.

Step Size

Number of Beams

MinimumObjectDetectionSize

5mm(0.2")

10mm(0.4")

20mm(0.8")

40mm(1.6")

80mm(3.2")

Maximum Scan Times (in milliseconds)

Array Length

Straight Scan

Single- Edge Scan

Double-Edge ScanStep

2 BeamsStep

4 BeamsStep

8 BeamsStep

16 BeamsStep

32 Beams163 mm(6.4") 5.8 1.8 3.4 2.7 2.5 2.6

325 mm(12.8") 10.6 1.9 8.1 5.1 3.6 3.0 2.7

488 mm(19.2") 15.0 2.1 11.5 6.8 4.5 3.4 3.0

650 mm(25.6") 20.1 2.1 14.9 8.5 5.3 3.9 3.2

812 mm(32.0") 24.9 2.1 18.3 10.1 6.1 4.2 3.5

975 mm(38.4") 30.0 2.1 21.7 11.8 7.0 4.7 3.6

1138 mm(44.8") 34.5 2.1 25.0 13.5 7.9 5.1 3.8

1300 mm(51.2") 39.3 2.1 28.4 15.2 8.7 5.5 4.1

1626 mm(64.0") 48.0 2.3 35.1 18.6 10.4 6.4 4.5

4.8

1788 mm(70.4") 53.6 2.3 38.5 20.3 11.2 6.8 4.7

Figure 5-14. The effect of step size on minimum object detection size

Figure 5-15. The effect of sensor length and scanning method on scan time (typical)



NOTE:Scantimesareexclusiveofserialcommunicationtransmissiontimes.

1463 mm(57.6") 44.0 2.2 31.8 16.9 9.5 5.9 4.3

1951 mm(76.8") 58.4 2.3 41.9 21.9 12.1 7.2 4.9

2 4 8 16 32

P/N64118rev.B


26

5.3.4 Scan Analysis Mode Selection

Thecontrolmodulemaybeprogrammed,ifdesired,foranyoneortwoofsevenScanAnalysis(measurement)Modes.Eachselectedmodemaybeassignedindividuallytoanoutput(seesection5.3.5or5.3.6).Thebeamsinthearrayarenumberedinsequence,withbeam#1locatedatthecabledendoftheemitterandthereceiver.

“Beam Location” Modes• First Beam Blocked (FBB): ThecontrolmoduleidentifiesthelocationoftheFirstBeamBlocked.

• First Beam Made (FBM):ThecontrolmoduleidentifiesthelocationoftheFirstBeamMade(unblocked).

• Last Beam Blocked (LBB):ThecontrolmoduleidentifiesthelocationoftheLastBeamBlocked.

• Last Beam Made (LBM):ThecontrolmoduleidentifiesthelocationoftheLastBeamMade(unblocked).

• Middle Beam Blocked (MBB):ThecontrolmoduleidentifiesthelocationoftheMiddleBeamBlocked,midwaybetweenthefirstandlastbeamsblocked.

“Beam Total” Modes• Total Beams Blocked (TBB): Thecontrolmoduletotalsthenumberofblockedbeams.

• Total Beams Made (TBM): Thecontrolmoduletotalsthenumberofmade(unblocked)beams.

• Contiguous Beams Blocked (CBB):Thecontrolmoduleidentifiesthelargestnumberofconsecutivelyblockedbeams.

• Contiguous Beams Made (CBM):Thecontrolmoduleidentifiesthelargestnumberofconsecutivelymadebeams.

• Transitions (TRN):Thecontrolmodulecountschangesfromblockedtoclearandcleartoblocked.Forinstance,ifbeams6-34areblocked,thenthereisaclear-to-blockedtransitionfrombeam5tobeam6,andablocked-to-cleartransitionfrombeam34tobeam35.Transitionmodecanbeusedtocountobjectswithinthearray.

TheAnalysisMode(s)programmedmaybeassignedtoanyoneoftheavailableoutputs(seeFigure5-18).EachoutputcanbesetforMEAS1, MEAS2, MEAS1 InvertedorMEAS2 Inverted.

5.3.5 Analog Output Configuration (Analysis Mode Assignment)

Analogoutputs#1and#2mayeachbeassignedtooneoftheanalysismodesdescribedinsection5.3.4.WhentheselectedScanAnalysisModeinvolvesfirstorlastbeamblockedormade(unblocked),theassignedoutputwillvaryinproportiontothebeamnumberidentifiedduringascan.WhentheScanAnalysisModeinvolvestotalbeamsblockedormade,thatassignedoutputwillvaryinproportiontothetotalbeamscountedduringascan.

Notethatthepull-downmenususedforassignmentoftheScanAnalysisModestotheanalogoutputsincludetwo“Inverted”selections.WheneitherMEAS1 InvertedorMEAS2 Invertedisselected,thatanalogoutputwilldecreaseasthemeasurementmodevalueincreases.Aninvertedoutputwillbeatfullscale(Spanvalue)whenthescananalysisvalueiszero;andatmaximumscananalysisvalue,theoutputwillbeattheNullvalue.

Figure 5-18. Assigning an Analysis Mode to each Analog Output

(PSF Configuration screen)

Figure 5-17. Examples of MINI-ARRAY scan analysis modes

Figure 5-16. Scan Analysis Mode Selection (PSF Configuration screen)

Last Beam Made (LBM)First Beam Made (FBM)

Receiver

Emitter

8

16

24

32

40

48

Last Beam Blocked (LBB)First Beam Blocked (FBB)

Receiver

Emitter

8

16

24

32

40

48

Total Beams Made (TBM)Total Beams Blocked (TBB)

Receiver

Emitter

8

16

24

32

40

48

InLastBeamBlockedmode,lastbeamis#43of48

InFirstBeamBlockedmode,firstbeamis#15of48

InLastBeamMademode,lastbeamis#37of48

InFirstBeamMademode,firstbeamis#26of48

InTotalBeamsMademode,34of48possiblebeamsaremade

InTotalBeamsBlockedmode,14of48possiblebeamsareblocked



P/N64118rev.B

TheNullandSpanrangesmaybeadjustedasfollows:

Toreadthenewvaluesonthemeter,clickonNullorSpan Update.ClickontheOKbuttontosavethenewsettingsandreturntheprogramtothePSFConfigurationscreen.ClickingontheCancelbuttonreturnstheprogramtothepreviouslysavednullandspansettings.

NOTE:NullandSpanarefactorysettospecifiedvaluesandusuallyrequirenochanges.

Scan #Providesawaytosmoothoutputresponseandavoidunstableanalogoutputconditions.Themenuallowsselectionoffrom1to9scans(seeFigure5-20).Foranalogoutputs,ifscan#issetatmorethan1,thescananalysisvalueisaveragedforalloftheselectednumberofconsecutivescans,preventingdipsandspikesintheoutputs.

Fortotalbeamvalues(TBBandTBManalysismodes),programmingofblankedbeams(section5.2.3)willaffecttheproportionalanalogoutputs.Blankedbeamsareignoredbothinthenumberofblockedormadebeamsandthetotalnumberofbeams.Forexample,ifa64-beamarrayhas20blankedbeamsand22oftheremaining44beamsareblocked,theoutputvalueswillbeatmid-range.

5.3.6 Zero Value

Zerovalueisusedtospecifytheanalogoutputwhenthemeasurementmodevalueiszero.TheusercanselectananalogoutputofLAST,NULL,orSPAN.

LAST: Outputholdsthelastnon-zerovaluebeforethelightscreenbecameclear.NULL: ProvidestheminimumvalueSPAN: Providesthemaximumvalue.

TheNull/SpanConfigurationscreen(Figure5-19),maybeusedtoadjustthezeroandfullscalereadingforeitheranalogoutput.TodisplaytheNull/SpanConfigurationscreen,clickontheNull/SpanbuttonatthebottomofthePSFConfigurationscreen(Figure5-9).Eachoutputisindependentandmustbeadjustedseparately.AdjusttheNullandSpanvalueseitherbymovingtheslidebars,orbyenteringanewvalueonthekeyboard.

To Measure:Analog Voltage Output:Connectthevoltmeterbetweenterminals10or16(+)and17(–).

Analog Current Output:Connecttheammeterbetweenterminals10or16(–)and1(+).

Analog Output Type

Null SpanMinimum Maximum Minimum Maximum

Voltage 10mV 2.3V 4.8V 10.1V

Current 3.9mA 7.8mA 11.9mA 20.2mA

Figure 5-19. Null/Span Configuration screen

Figure 5-20. Scan # (PSF Configuration screen)

Figure 5-21. Zero Value (PSF Configuration screen)



NOTE:WhenintheNull/Spanscreen,thecontrollerwillhaveadiagnosticcodeof8.

P/N64118rev.B



5.3.7 Discrete Output Configuration (Analysis Mode Assignment)

Discreteoutputs#1and#2(“Alarm”)mayeachbeindividuallyassignedtooneoftheScanAnalysisModesprogrammedinsection5.3.4(seeFigures5-16and5-22).

NexttoeachdiscreteoutputassignmentmenuareLowandHigh Set Pointboxes.Thenumberineachboxidentifiesabeaminthearray(beam#1beingclosesttothecabledendoftheemitterandthereceiver).TheLowandHighSetPointsmaybechangedbyclickingonaboxandenteringanewnumber.

WhentheselectedScanAnalysisModeinvolvesfirstorlastbeamblockedormade(unblocked),theassignedoutputwillenergizewhenthebeamidentifiedduringascanfallswithintherangeofthesetpoints.WhentheScanAnalysisModeinvolvestotalbeamsblockedormade,thatassignedoutputwillenergizewhenthevalueoftotalbeamscountedduringascanfallswithintherangeofthesetpoints.

Notethatthepull-downmenususedforassignmentoftheScanAnalysisModestothediscreteoutputsincludetwo“Inverted”selections.WheneitherMEAS1 InvertedorMEAS2 Invertedisselected,thatdiscreteoutputwillde-energize(turnOFF)wheneverascananalysisvaluefallswithintherangeofthesetpoints.

Hysteresisvaluesforeachendofthesetpointrangemayalsobeset(Figure5-22).Hysteresisdeterminestheamountofchangethatmustoccurateachsetpoint(HighandLow)tocausetheassociatedoutputtochangestate.Hysteresispreventsunstableoutputconditionswhenthescananalysisvalueexactlymatchesoneofthesetpoints.ThedefaulthysteresissettingisonebeamlessthantheLowSetPointandonebeammorethantheHighSetPoint.

Scan #Providesanotherway,inadditiontohysteresissettings,tosmoothoutputresponse.Outputsareupdatedonlyaftertheselectednumberofidentical(withinthehysteresislimits)scans.Themenuallowsselectionoffrom1to9scans.Fordiscreteoutputs,thescananalysisvaluemuststayeitherinsideoroutsidethehysteresislimitsforalloftheselectednumberofconsecutivescans,inorderfortheoutputtorespond.SeeFigure5-23.

Alarm and TriggerDiscreteoutput#2(only)hastwoadditionaloptions:AlarmandTrigger.

Alarm:Output#2energizeswhenevertheSystemdetectsasensorerror(suchasadisconnectedcable)orwhenevertheexcessgainofoneormorebeamsbecomesmarginal.

Trigger: canbeusedtogateasecondcontrolmodulewhenContinuousScanMethodisalsoused.Whenthecontrolmoduleisinstraightscanningmode,Trigger ChannelNumberdefinesthebeamnumberduringascanatwhichthetriggeroutputwilloccur(Figure5-23).TheTriggeroutputisa100microsecond(0.0001sec.)pulse.Ifthecontrolmoduleissetforsingleordoubleedgescan,theTriggerpulsewillcomeattheendofthescan(Trigger Channel Numberwillbeignored).

Figure 5-23. Scan # (PSF Configuration Screen)

Figure 5-24. Trigger Channel

Figure 5-22. Assigning an Analysis Mode to each Discrete output (PSF Configuration screen). Alarm and Trigger output options are available only for Discrete Output #2.


P/N64118rev.B

5.4 Serial Communication with a Host Controller

ThecontrolmodulecommunicateswithahostprocesscontrollerviaRS-232orRS-485protocolandatthebaudratespecifiedintheSerialCommunicationsbox(section5.3.1).TheSystemprovidesanumberofdatatransmissionoptions.

5.4.1 Serial Data Transmission

TheserialtransmissionportionofthePSFConfigurationscreenactivatestheserialport(s),specifiesthedataformat,andprovidesdatasuppressionoptions.Thesesettingsarerequiredtoallowacontrolmoduletocommunicatewithahostcomputerorprocesscontroller.IfNo Serial Communicationisselected(thedefaultsetting),theserialport(s)willnottransmitsensingdata.

Measurement Mode Result: datatransmittedwillbethevaluesoutputfortheScanAnalysisModeselections.UptotwoScanAnalysisModeselectionscanbeactive.

ALL Mode: thestatusofeachbeaminthelightscreenarraywillbetransmittedforeach scan. InALLmode,blankedchannelsaretransmittedasunblocked(orclear)beams.

Max Meas Mode: thecontrolmodulerecordsthemaximummeasurementvalueregisteredwhilethelightscreenisblocked.Thatdatamaybetransmittedtothehosteitherwhenthearrayisclearattheendofthesensingevent(selectSend On Clear),orwhenpromptedbythehost(selectSend On Request).Thismodereducestheamountofserialdatasent.

5.4.2 Transmission Type

Transmissiontypedefinestheformatinwhichdataissent.TheASCIIoptioncausesthecontrolmoduletosenddatainthreeASCII-codedbytes.TheBinaryoptioncausesdatatobesentinbinaryformat,reducingtheamountofdatapermeasurementmodefromthreebytestotwo.Formoreinformationonthedataformats,refertoAppendixA.

Figure 5-25. Serial Data Transmission options (PSF Configuration screen)




P/N64118rev.B



5.4.3 Serial Options

TheSerialOptionsboxprovidestwooptions:Suppress Clear DataandSuppress Header.

Suppress Clear Dataprovidesonemethodtoreducetheamountofdatabeingtransmittedbythecontrolmodule,accomplishedbynotsendingdatawhennoobjectisdetected.Thecontrolmoduletransmitsserialdataonlywhenoneormoreunblankedbeamsofthelightscreenarrayareblocked.Whenthearraygoesfromblockedtoclear,dataissentoneadditionaltime,indicatingtheclearcondition.

Suppress Headerisusedtopreventtransmissionofthethree-byteidentificationstring(“headerstring”)associatedwitheitherASCIIorBinarydataformats.Theheaderstringconsistsoftwobytesatthestartofthedata,andaterminationbytetomarktheendoftheserialtransmission.SeeAppendixAformoreinformationonserialdataformats.

5.5 Transfer of PSF to the Control Module

AftermakingalloftheselectionsinthePSFConfigurationscreen,thePSFmaybesenttothecontrolmodulebyclickingtheSend PSFbutton(seeFigure5-26).ThiscommandloadsthePSFintothenon-volatilememoryofthecontrolmodule,andautomaticallyoverwritesthecurrentPSF.TheprogramwillconfirmthatthePSFwasaccepted,orwillnotifytheuserofchangesrequiredtothePSF.

TocheckthevaluesofthePSFcurrentlyloadedintothecontrolmodule,selectUpload PSF.ThecurrentPSFwillbedisplayedonthePSFConfigurationscreen.

Figure 5-26. PSF Output options (PSF Configuration screen)


P/N64118rev.B

System Diagnostics


5.5.1 Saving and Recalling PSF Files

ToplacethedisplayedPSFintoafilethatcanberetrievedatanytime,selectFile Save PSF (Figure5-26).WhenaskedifyouwanttosavethePSFtoafile,selectYes.AsubscreentitledFileSavewillappear(Figure5-27).Overtype‘*.psf’intheFileNameentryboxwiththenameofthefiletobestored(upto8characters),plusthe.psfextension;thenselectOK(orpressEnter).ThePSFwillbestoredontheselecteddrive(defaultis‘c:’)andtheprogramwillautomaticallyreturntothePSFConfigurationscreen.

ToretrieveafiledPSF,selectFile Retrieve PSF.TheFileBoxsubscreenwillappear(Figure5-28).SelectthedesiredPSFfromtheFileNamelistandselectOK(orpressEnter).TheselectedPSFwillloadtothePSFConfigurationscreen,anditcanthenbeloadedintothecontrollerusingtheSend PSFcommand.

5.5.2 PSF Output Analysis

ToviewactivityinthearrayinresponsetothecurrentlyloadedPSF,selectExecute (Figure5-26).TheMeasurementOutputscreenwillappear(Figure5-29);selectRun.Thetablewilldisplaythestatusfortheselectedmeasurementmode(s),includingthePresentvalueandtheHighandLowvaluesfortheRunperiod.

SelectStopto“freeze”thedata.SelectSteptoinitiateasinglescanofthearraytosimulatea“snapshot”ofwhatisviewedbythearrayattheinstantthatStepisselected.

UseoftheExecutecommandisespeciallybeneficialfortestingtheresponseofagatedsystem.RunsimulatestheContinuousScanningmode,andStepsimulatesagateinputcommand.

5.5.3 Quit and Exit

ToclosethePSFConfigurationscreen,selecteitherQuitorExit (Figure5-26).SelectingQuiterasestheEditPSFScreenandsendstheuserbacktotheMainWindow;thepresentPSFScreenvaluesarenotretained.TheExitcommandissimilartotheQuitcommand,excepttheuserwillbepromptedtosavetheconfigurationvaluestoaparametersetupfile(PSF).

Figure 5-27. FileSave subscreen of the PSF Configuration screen, accessed with the File Save PSF command

Figure 5-28. FileBox subscreen of the PSF Configuration screen, accessed with the File Retrieve PSF command

Figure 5-29. Measurement Output subscreen of the PSF Configuration screen, accessed with the Execute command

P/N64118rev.B

System Diagnostics


6. System DiagnosticsSystemdiagnosticsmaybeperformedusingthestatusanddiagnosticsindicatorsonthecontrolmoduleandsensors,orbyusingtheDiagnosticssoftwareroutine,oracombinationofthetwo.

6.1 Diagnostics Indicators

NOTE:Statusindicatorsappearto“freeze”ifthecontrollerhasbeenconfiguredforGateorHostmode(Section5.3.2),andnosignalispresenttocauseascanupdate.

DIAGNOSTICSError No. Error Type/Action

– System is OK

A / b Align / blank• Status

1 Output Short• Checkoutputload&wiring

2E / R Mismatch• Systemmustusesamelengthemitterandreceiver

3Receiver Error• Checkreceivercable•Replacereceiver

4Emitter Error• Checkemittercable•Replaceemitter

5 Serial Comm• Checkserialcable

6EEPROM• ReconfigurePSF•Replacecontrolmodule• Reconfigureblanking

7 CPU Error• Replacecontrolmodule

8 Null / Span• Status

Figure 6-2. Key to System Diagnostics Indicator codes

Red OperationalLED

Green Alignment LED

Red Blocked LED

Yellow MarginalAlignment LED

High-ResolutionEmitter

High-ResolutionReceiverDIN-Rail-Mountable

Control Module


ALIGNMENTSWITCH

POWER

POWER


2 - TX3 - RX5 - COM

RS-232

MAHCVP-1

OUTP

UT

ALAR

M

GATE

ALIG

N

1

+ –

+ –

16-30V dc1A MAX

10-30VDCGATE

D OUT 1 150mA MAX

0-10VOLTS25mA (MAX)

V OUT 1

EMTR RCVR

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F1 +12V COM DRN T/R T/R

BR BU BK WH

TX TX+ –

10-30VDCALIGN

0-10VOLTS25mA (MAX)

V OUT 2+V

ALARM150mA MAX

+V

Diagnostics Indicator

Alignment Button

Red Discrete Output #1 LEDRed Alarm (Discrete Output #2) LED

Red Gate LEDGreen Align LED

RS-232 Port

Figure 6-1. A-GAGE High-Resolution MINI-ARRAY System diagnostics and status indicators

Bright,easy-to-seeLEDindicatorsonbothsensorsandonthefrontpanelofthecontrolmoduleprovideanongoingdisplayofthesystem’soperatingstatus.

Control Module:OUTPUT:(red)displaysthestatusofDiscreteOutput#1.

ALARM: (red)displaysthestatusofDiscreteOutput#2.Thisoutputmaybeassignedtoananalysismode,oritmaybeusedasaSystemDiagnosticsalarmorasaTriggeralarmtogateanotherA-GAGEHigh-ResolutionMINI-ARRAYSystem.

GATE:(red)displaysthestatusoftheGateinput.

ALIGN: (green)indicatesproperemitter/receiveralignmentandaclear,unblockedlightscreen.ThisindicatorisONwheneitherthegreenorboththegreenandyellowLEDsofthereceiverareON.


P/N64118rev.B

System Diagnostics


Diagnostics Indicator: Thisbright,segmentedLEDdisplayonthecontrolmodulefrontpanelindicatesoneof10Systemstatusconditions,plusthepresenceorabsenceofblanking.(BlankingONcausesaperiodtoappearintheDiagnosticsIndicatorwindow,inadditiontotheSystem’sotherstatuscondition.)SeeFigure6-2forthekeytotheseerrortypesandstatusconditions;thischartisalsolocatedonthesideofthecontrolmodule.

Emitter: OPERATIONAL:(red)LEDindicatespowertotheemitterisON,andunitisoperational.

Receiver: BLOCKED: (red)LEDindicatessomeofthearraybeamsareblocked.

MARGINAL:(yellow)LEDindicatesthatarrayalignmentismarginal.

ALIGNMENT: (green)LEDindicatesthatarrayalignmentissatisfactory.

Toimprovealignment,adjustthepositionoftheemitterandreceiveruntilthegreenLEDlights,makingsurethatnounblankedbeamsareinterrupted.ThenuseoneofthemethodsinSection5.2torealignthesystem.

6.2 Diagnostics Routine

EmitterorreceiverproblemsmaybefurtherdiagnosedusingtheDiagnosticsroutineincludedwiththeMINI-ARRAYsoftware.LaunchtheprogrambyselectingDiagnosticsundertheMINI-ARRAYmenu(Figure5-2)orbypressingF2.

TheDiagnosticsscreen(Figure6-3)displaysthesizeofeachemitterandreceiver(expressedinthenumberof64-element“boards”itcontains)anditsfunctionalstatus(orstate).Ifanerrorhasoccurred,thespecificproblembeamchannelisidentified.Additionally,ifthereisaproblemwithanemitterorreceivercableconnection,a“No Response”messageisdisplayed.

TheDiagnosticsroutinealsodisplaysthepartnumberanddatecodeofthecontroller,informationthatmaybeusefuliffactory-assistedtroubleshootingbytelephoneisrequired.

Figure 6-3. Diagnostics screen, accessible from the MINI-ARRAY menu

P/N64118rev.B

Appendix A: Data Transmission



A.1 Host Mode Command String

Asdiscussedinsection5.3.2ofthismanual,thecontrolmodulehasthreecontrolmodeoptions:continuous,gate,andhost.Hostmoderequiresaserialtransmissionstringfromaseparatedevice,typicallyaPCorprocesscontroller.TheserialtransmissionmediumcanbeeitherRS-485orRS-232.

WhenHostcontrolmodeisselected,thehostprocesscontrollerinitiatesscansusingacommandstring.Thecommandstringisathree-bytemessage,consistingof:

•Controlbytewithdecimalvalue248,

•ControllerID(theidentificationofaspecificcontrolmoduleonthestring,indicatedbyoneof15ASCIIlettersAthroughO,andspecifiedinthePSF),and

•Scaninitiationbyte(ASCIIletterS).

Thecommandstringisfurtherdefinedasfollows:

/*the below C code will define an array called msg that will contain the Host Scan Command */ unsigned char msg[3]; /*declare three byte unsigned character array using C language */ msg[0]=248; /*control byte */ msg[1]=65; /*assume the controller ID is the letter A */ msg[2]=83; /*assume initiation byte which is the ASCII letter S */

Thehosttransmitsthisthree-bytemessageatthedefinedbaudrate.Theformatisonestartbit,onestopbit,evenparity,andeightdatabits.Whenthecontrolmodulereceivesthismessage,itinitiatesascan(assumingHostmodeisselected)andthenupdatesitsoutputsasrequired.ThecontrolmodulethenwaitsforthenextHostCommandmessagebeforeinitiatinganotherscan.

A.2 Serial Data Format and Header String

Theprogrammedmeasurementmodeormodesdeterminethetypeofinformationthatisseriallytransmitted.ForexampleifMeas1issetforFBBandMeas2issetforLBB,thenthedatatransmittedtothehostcontainsthevaluesofthefirstandlastbeamblocked.TheAllmeasurementmodeprovidesthestatusofallbeamstothehost.

Inadditiontomeasurementmodeinformation,thedatatransmissionalsocontainsatwo-bytestartstringandaterminationbyte.Thestartstringconsistsofafirstbytethatdoesnotchange,followedbythecontrollerID.Thefirstbytevalueisahex1Cor28decimal.Attheendofthestring,thecontrolmodulewillplaceaterminationbyte.TheterminationbyeistheASCIIcharacterforalinefeed(hexvalue0A).ThesethreebytescollectivelyarecalledtheSerialHeaderstring.

Figure A-1. Serial Transmission options (PSF Configuration screen)


P/N64118rev.B

A.2.1 ASCII Format Data Transmission

TherearetwowaystouseASCIIformattorepresentdata.Theoneuseddependsuponwhichmeasurementmodesareselected.

For ALL measurement mode,eachdatabyteispresentedinaneight-bitASCIIformatthatconveysthestatusoffourconsecutivechannels(fourconsecutivebeams).Eachsubsequentbyteconveysthestatusofthenextfourchannels,untilthestatusofeverychannelisreported.TheallowabledatavaluesforAllmeasurementmodeareASCIInumbers0to9andASCIIlettersAtoF.Inthetable,a‘0’representsanunblockedbeamchannel,and‘1’representsablockedchannel.

Forexample,assumethata64-channelsystemhasbeenconfiguredfortheAllmeasurementSerialtransmissionoption.Channels1through4areblocked,asischannel63.Theserialstringstartswith0x1c,andtheID(assumean‘A’)followedby16ASCIIvaluesandterminatedwith0x0A.Thestringwouldappear:

0x1c, ‘A’, ‘F’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’0’, ‘0’,’4’, 0x0a

Thestringshowsthatbeams1through4areblocked,asisbeam63.Allotherbeamsareunblocked.Iftheuserhadrequestedsuppressionoftheheader,then0x1c,‘A’,andthe0x0awouldhavebeendeleted.

For transmitting Measurement mode data,usethreeASCIIbytestorepresenteachmeasurementmode.Forexample,ifMeas1isFBB,Meas2isLBB,themeasuredvaluesare6and120,andthecontrollerIDisB,thedatastringisasfollows:

0x1c ‘B’, ‘0’, ‘0’, ‘6’, ‘1’, ‘2’, ‘0’, 0x0a

AswithALLmode,theheaderandcleardatacouldbesuppressed.Forcleardatasuppression,thecontrolmodulesendsthestatusofaclearconditiononlyonthefirst“clear”scan.Afterthat,thecontrolmodulewillcontinuetoscanbutwillnottransmitdatauntilthesensorisagainblocked.

A.2.2 Binary Format Data Transmission

SimilartoASCIIformat,binaryformatmaybeusedtorepresentdataintwoways.OnemethodinvolvestheAllDatatransmissionmode;theother,Measurementmode.

For All Data transmission mode,thecontrolmodulerepresentsthestatusofeightconsecutivedatachannelsforeachbyte.Eachbitofeachbyteisdirectlyrelatedtothestatusofanindividualchannel.Thefirstdatabyterepresentschannels1through8;theseconddatabyterepresentschannels9through16.ThebitpatternforthefirstandseconddatabytesisasshowninFigureA-3.

Foreachbitposition,1representsablockedbeamand0representsanunblockedbeam.

Forexample,fora64-channelsystemwithbeams1-6blocked,beam43blockedandbeams62-64blocked,thedatatransmittedfromcontrolmodule‘A’isasfollows:

0x1c, ‘A’, 0xFC, 0x00, 0x00, 0x00, 0x00, 0x20, 0x00, 0x07, 0x0A

Thisstringwouldhavethestartbyte,controllerID,followedbytheeightdatabytesandterminatedwiththe0x0A.Theheaderbytesmaybesuppressedifnecessary.



Figure A-2. ASCII data values

Definitions for ASCII Data ValuesFortheALLmeasurementmode

Character Ch 4 Ch3 Ch2 Ch1

F 1 1 1 1

E 1 1 1 0

D 1 1 0 1

C 1 1 0 0

B 1 0 1 1

A 1 0 1 0

9 1 0 0 1

8 1 0 0 0

7 0 1 1 1

6 0 1 1 0

5 0 1 0 1

4 0 1 0 0

3 0 0 1 1

2 0 0 1 0

1 0 0 0 1

0 0 0 0 0

First Data Byte Second Data Byte

ChannelBit

Position ChannelBit

Position1 7 9 7

2 6 10 6

3 5 11 5

4 4 12 4

5 3 13 3

6 2 14 2

7 1 15 1

8 0 16 0

Figure A-3. Binary data values

P/N64118rev.B



For Measurement mode analysis,thebinaryformatusestwodatabytesforeachmeasurementmode.(Ifwehaveonemeasurementmode,thentherearetwodatabytes.Fortwomeasurementmodes,therearefourdatabytes.)

Forexample,assumethatcontrolmodule‘B’isconfiguredforonemeasurementmode(FBB),andthevalueis78.Thestringfromthecontrolmoduleisasfollows:

0x1c, ‘B’, 0x00, 0x4E, 0x0A.(atotaloffivebytes)

or

0x00, 0x4E(atotaloftwobyteswithSuppressHeaderoption)

Nowassumethatcontrolmodule‘B’isconfiguredforFBBandLBBwithvaluesof74and303,respectively.Thestringfromthecontrolmoduleisasfollows:

0x1c,’B’, 0x00, 0x4A, 0x01, 0x2F, 0x0A(atotalofsevenbytes)

or

0x00, 0x4A, 0x01, 0x2F(atotaloffourbyteswithSuppressHeaderoption)

A.3 Max Meas Mode Command String

MaxMeasModecausesthecontrolmoduletoretainthemaximummeasurementvaluesforagivenobject.ThesevaluesaretransmittedeitherimmediatelyafterthecontrolmoduleisclearedorwhenpromptedbytheHost.TheMaxMeasModeCommandStringisafour-bytestringthatappearsasfollows:

• Controlbytewithdecimalvalue248

• ControllerID(oneof15ASCIIlettersAthroughO,asspecifiedinthePSF)

• MaxMeasCommandTransmit(ASCIIletterT).

• Terminationbytewithdecimalvalue13

Thecommandstringisfurtherdefined:

/*the below C code will define an array called msg which will contain the Max Meas Mode Command String*/

unsigned char msg[4]; /*declare four byte unsigned character array using C language */msg[0]=248; /*control byte */msg[1]=65; /*assume the controller ID is the letter A */msg[2]=84; /*assume initiation byte which is the ASCII letter T */msg[3]=13; /*termination byte */

Whenthehostsendsthisstring,thecontrolmodulesendsthemaximumvaluesstoredfromthepreviousscannedobject.Ifthesensorispresentlyscanninganobjectwhenthemessageissent,thecontrolmodulewillgivethemaximumvaluesforthepresentobject.


P/N64118rev.B


psanchez

Sticky Note


P/N64118rev.B

Appendix B: Glossary


Appendix B: Glossary

Blanked Beam: Abeamthatis“ignored”bythereceiver,asaresultofablankingprogrambeingappliedtoit.Beams(orgroupsofbeams)areblankedwhenacomponentorfixturewillremaininormovethroughthelightscreenarray;blankingtheaffectedbeamspreventsthecomponentorfixturefromcausingfalseoutputs.

Blocked Beam: Abeamthatisobstructedbetweentheemitterandthereceiver,andisnotblanked.

Clear Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasamadeorunblockedbeam).

Excess Gain: Ameasurementoftheamountoflightfallingonthereceiverfromtheemitteroverandabovetheminimumamountrequiredforoperation.A-GAGEHigh-ResolutionMINI-ARRAYemittersandreceiversautomaticallyperformanAlignmentproceduretoequalizetheamountofexcessgainateachelementalongthearray.

Host: AcomputerorprocesscontrollerthatcontrolsandreceivesinputfromtheHigh-ResolutionMINI-ARRAYSystem,and/orotherequipmentandsystemswithinafactory.

Made Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasanunblockedorclearbeam).

Unblocked Beam: Abeamthatrunsunobstructedfromtheemittertothereceiver(sameasamadeorclearbeam).


P/N64118rev.B


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Documents

A-GAGE® High-Resolution MINI-ARRAY® Instruction Manual