Banner A-GAGE MINI-ARRAY User Manual

®

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A-GAGE

MINI-ARRAY

®

Two-Piece Measuring Light Screen

Configured for Vehicle Separation

2 Discrete Outputs with EIA-485 Communication

Instruction Manual

Features

• Simple two-piece measuring light screen for inspection,
profiling, and object detection, tailored for vehicle
separation applications.

• Detects single-fault emitter, receiver and dirty lens
conditions; continues to function in single-fault
conditions.

• Diagnostic LEDs provide a simple means of monitoring
sensor performance.

• The sensor algorithm ignores objects up to 125 mm (5")
while detecting automobile trailer hitch profiles as small
as 25 mm (1").

• Models available with array lengths from 150 to 1220 mm
in 150 mm increments (6" to 4' in 6" increments) plus
1520 mm (5') and 1830 mm (6') models.

• Beam spacing 19.1 mm (3/4").

• Two discrete outputs plus EIA-485 serial communication.

• System is configurable via the EIA-485 serial interface.

• Alarm output signals dirty lens and system fault
conditions.

• EIA-485 serial communication enables a computer to
process scan data and system status.

WARNING . . .

Never use these products as sensing devices for personnel protection. Doing so could lead to serious injury or death.

These sensors do NOT include the self-checking redundant circuitry necessary to allow their use in personnel safety applications. A
sensor failure or malfunction can cause either an energized or de-energized sensor output condition. Consult your current Banner
Safety Products which meet OSHA, ANSI and IEC standards for personnel protection.

Printed in USA 04/10 P/N 117167 rev. A

Not To Be Used for Personnel Protection

1.0 System Overview

The Banner A-GAGE MINI-ARRAY Two-Piece Measuring Light Screen was
customized for vehicle separation applications. It incorporates the popular
MINI-ARRAY emitter and receiver design and ease of use, while simplifying
installation. This two-piece system does not require a separate controller.

A typical system consists of four components:

• Emitter

• Receiver

• Two interconnecting cables

Models are available in array lengths from 150 to 1220 mm in 150 mm increments
(6" to 4' in 6" increments), plus 1520 mm (5') and 1830 mm (6') lengths. Models
are listed in Section 2.1. Beam spacing is 19.1 mm (3/4"). Sensing range is 0.9 to
15 m (3' to 50').

MINI-ARRAY

Two-Piece Measuring Light Screen

®

Figure 1-1. Typical vehicle separation application

2 P/N 117167 rev. A

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

www.bannerengineering.com • Tel: [phone]

MINI-ARRAY

Emitter

Receiver

Red
Operational
LED

Green Alignment LED

Red Blocked LED

Yellow Marginal
Alignment LED

Two-Piece Measuring Light Screen

®

System Overview

1.1 System Features

Built-in features simplify the operation of the MINI-ARRAY Two-Piece Light Screen
system, which is customized to specifically address the demanding requirements
needed to reliably detect vehicle separation. Large optical lenses provide strong
optical excess gain (needed for demanding outdoor environments).

The system is pre-configured for an interlaced optical pattern, which provides
the minimum object detection necessary to detect a trailer hitch. A sensor scan
involves individually enabling each emitter channel twice. In effect, each emitter
channel fires at both its opposing receiver element, and at the one beneath it.
The result is an interlaced optical detection pattern, as shown in Figure 1-3. This
pattern can better detect objects within the middle third of the sensing area.

Along with using the interlaced pattern, the sensor processes the scan data in
a method that is tailored for Vehicle Separation applications: both for initial car
detection and trailer detection (see Sections 1.2 and 1.3). Several important
features have been built into the MINI-ARRAY Two-Piece system:

• Easy-to-understand diagnostic LEDs

Figure 1-2. System features

• 2 discrete outputs

• EIA-485 serial communication

• Self-diagnostics to detect dirty lens, faulty or degraded sensor operation
conditions

Interlaced Scan improves optical
resolution in the middle one-third
of the scanning range.

Emitter

Receiver

Figure 1-3. Interlaced scan

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

P/N 117167 rev. A 3

www.bannerengineering.com • Tel: [phone]

System Overview

Two-Piece Measuring Light Screen

1.1.2 Easy-to-Understand Diagnostic LEDs

The system provides simple, straightforward indications of sensor performance
(see Figure 1-2). See Section 3.3 for a more detailed guide to troubleshooting
system status using the diagnostic LEDs.

Emitter: 1 Red Diagnostic LED

LED Condition ON Solid OFF Flashing (5x per second) Flashing (1x per second)

MINI-ARRAY

®

Emitter Condition

Sensor is functioning
normally

No power to emitter

Receiver is removed from
the system

Receiver: 3 Diagnostic LEDs (Green, Red, and Yellow)

The combined status of the Green and Red LEDs provides a simple sensor
alignment process. The Yellow LED signals a dirty lens or degraded sensor
condition (see Section 1.4).

LED Condition ON Solid OFF Flashing (2 Hz)

Green

Red

Yellow

Light screen is
unobstructed

Light screen is
obstructed

Dirty lens (whether
light screen is blocked
or clear); will remain
ON until receiver
detects proper light
signal strength

Light screen is
obstructed

Light screen is
unobstructed

Non-functioning emitter

Non-functioning emitter

Light signal of one or more beam(s) is degraded

1.1.3 Two Solid-State Outputs

One or more emitter optical
channel(s) not working
properly

The receiver has two discrete outputs (Output #1 and Output #2). Each output is
independent and can be configured for either NPN or PNP operation. The sensor
is factory-configured for NPN outputs, with Output #1 designated for vehicle
separation detection and Output #2 for sensor “health” status output. These
outputs are rated to 150 mA and are short circuit protected.

1.1.4 EIA-485 Interface

To provide sensor profiling and system status information, the receiver has a serial
EIA-485 interface. Please see Appendix A for further information.

1.1.5 Sensing Scan Time

Sensing scan time is a function of the sensor length and number of beams
interrogated (i.e. steps) per scan of the array. The models table in Section 2.1
provides scan times for the Vehicle Separation scanning application (labeled as
interlaced scanning) for each light screen size. The worst-case response time is
twice the scan time.

4 P/N 117167 rev. A

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

www.bannerengineering.com • Tel: [phone]

MINI-ARRAY

Two-Piece Measuring Light Screen

®

System Overview

1.1.6 Supplied System Software

The system provides other scanning modes and operation features, which are not
optimized for vehicle separation but are useful for other applications.

These features are easily accessed via a simple-to-use Banner-supplied PC
software program and an appropriate EIA-485 interface (consult a Banner
Engineering representative for more information). The PC software can be run
on any computer running Windows® 98, NT, ME, XP or 2000. The menu-driven
program walks the user through the many scanning and output options. After the
desired options are selected, download the settings to the receiver; the receiver will
store the configuration settings in non-volatile memory.

This software also enables the user to check sensor alignment, obtain sensor
readings, and verify sensor status. The built-in system diagnostics can be used to
assess emitter and receiver hardware errors or dirty lens locations.

1.2 Vehicle Detection Applications (Output #1)

The MINI-ARRAY Two-Piece Light Screen features a superior interlaced (cross­hatched) beam pattern. When the light screen is clear (no object is obstructing
the receiver’s view of the emitted beam pattern), the sensor will ignore small
objects while waiting to detect the beginning of a vehicle. Up to 125 mm (5”) of
consecutive light channels must be blocked before a valid object is detected; once
the sensor detects 125 mm or more of consecutive blocked light, Output # 1 will
become active (output ON).

1.3 Trailer Hitch Detection Applications (Output #1)

Once an object is detected (see Section 1.1.1), Output #1 will remain active until
the receiver again detects the entire emitter beam pattern (sensor is clear). The
interlaced scan pattern will detect smaller objects after initially detecting a vehicle,
even if only one beam is obstructed. Once the receiver detects a fully unobstructed
light screen, Output #1 again will become inactive (output OFF).

1.4 System Self-Diagnostics (Output #2)

Advanced electronic and data processing allows the receiver to continually monitor
and evaluate light signal quality and alert the user to light signal degradation or
sensor faults. The sensor can detect marginal alignment, permanently blocked
channels, a faulty emitter element, or a non-functioning emitter.

This receiver was designed to detect system failures and remain operational.
Potential problems include a dirty lens that totally blocks (occludes) the optical
light signal or a light signal failure (caused by either the emitter or receiver).
Although sensor failures are rare, the Two-Piece MINI-ARRAY has been designed
to continue to function while warning the user of fault conditions, minimizing
system down time and providing advance notice that system maintenance or
repairs are required.

Whenever the receiver detects proper operation, Output #2 is active (ON). When
the sensor detects a system problem (either a sensor fault or a degraded signal),
Output #2 is disabled (goes OFF, an alarm condition).

A system problem is acknowledged in three ways:

1. The condition of the diagnostic LEDs,

2. Output #2 will be inactive (OFF), and

3. The condition can be transmitted to the monitoring system, via the EIA-485
interface (see Appendix A, System Status Information: command 0x66).

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

P/N 117167 rev. A 5

www.bannerengineering.com • Tel: [phone]