Banner EZ-ARRAY USB Serial Adapter User Manual

A-GAGE® EZ-ARRAY™ Instruction Manual

Two-piece sensing array with 2 analog and 2 discrete outputs, plus serial output

Features

A cost-effective, two-piece measuring light curtain designed for • quick and simple installations with the sophistication to handle the toughest sensing applications

Excels at high-speed, precise process monitoring and inspection, • profiling, and web-guiding applications

A comprehensive combination of scanning options: • – 14 measurement (“scan analysis”) modes – 3 scanning methods – Selectable beam blanking – Selectable continuous or gated scan initiation – Selectable threshold setting for semi-transparent applications – 2 analog outputs, 2 discrete outputs, plus Modbus 485-RTU

serial output

Outstanding 4 meter range with 5 mm beam spacing•

Available in 12 lengths from 150 mm to 2400 mm•

Excellent 5 mm minimum object detection or 2.5 mm edge • resolution, depending on scanning method

Receiver user interface for quick, intuitive setup of many common • applications: – 6-position DIP switch for setting scan mode, measurement mode, analog slope, discrete output 2 option (complementary measurement or alarm operation) – 2 push buttons for gain method selection and alignment/ blanking – 7 Zone LEDs for instant alignment and beam blockage information – 3-digit display for sensing information and diagnostics

Software PC interface available for advanced configuration setup•

Remote teach wire option for alignment, gain settings, inverted • display, and DIP switch disable

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 catalog for safety products which meet OSHA, ANSI and IEC standards for personnel protection.

Not To Be Used for Personnel Protection

Printed in USA 09/12 P/N 130426 Rev. C

Table of Contents

1. Overview ........................................ 1

1.1 System Components ..............................1

1.2 Features ........................................2

1.3 Conﬁguration via DIP Switch or PC Interface ...........2

1.4 Status Indicators..................................3

1.5 Receiver Gray (Remote Teach) Wire.................. 4

1.6 Scanning Method ................................. 5

1.7 Gain Conﬁguration ................................ 7

1.8 Electronic Alignment Routine ........................8

1.9 Blanking ........................................8

1.10 Measurement Mode Selection . . . . . . . . . . . . . . . . . . . . . . 8

1.11 Analog Output Conﬁguration .......................9

1.12 Discrete Output Conﬁguration ......................9

1.13 Serial Communication ............................9

2. Components and Speciﬁcations .................... 10

2.1 Sensor Models .................................. 10

2.2 Cordsets and Connections......................... 11

2.3 Alignment Aids .................................. 11

2.4 Accessory Mounting Brackets and Stands............. 12

2.5 Replacement Parts ............................... 12

2.6 Speciﬁcations ...................................12

2.6 Speciﬁcations, continued ..........................13

2.7 Emitter and Receiver Dimensions ...................14

2.8 Standard Bracket Dimensions ......................15

3. Installation and Alignment ......................... 16

3.1 Mounting the Emitter and Receiver ..................16

3.2 Mechanical Alignment ............................17

3.3 Hookups .......................................18

3.4 Optical Alignment ...............................19

4. Using the Receiver User Interface................... 20

4.1 Conﬁguration DIP Switch ..........................20

4.2 Alignment / Blanking Button (Electronic Alignment)....... 21

4.3 Gain (Sensitivity Adjust) Button ..................... 21

4.4 Inverting the 3-Digit Display ........................22

4.5 Troubleshooting and Error Codes ................... 22

5. Using the PC Interface (Banner Sensors GUI) ......... 23

5.1 Supplied Software ...............................23

5.2 Communications Connections ......................23

5.3 Accessing the GUI ...............................23

5.4 Factory Defaults .................................25

5.5 Alignment and Blanking ...........................25

5.6 Conﬁguration Setup

5.7 System Conﬁg View ..............................27

5.8 Analog Output Conﬁg View ........................28

5.9 Discrete Output Conﬁg View ....................... 28

5.10 Comm Conﬁg View..............................29

5.11 Part Number and Version Info View .................29

5.12 System Diagnostics View.........................29

5.13 Communications Troubleshooting .................. 30

Appendix A. Modbus Reference ....................... 34

Glossary ....................................... 45

...............................26

A-GAGE EZ-ARRAY

Instruction Manual

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A-GAGE EZ-ARRAY

Instruction Manual

1. Overview

Overview

The A-GAGE™ EZ-ARRAY™ measuring light screen is ideal for such applications as on-the-ﬂy product sizing and proﬁling, edge-guiding and center-guiding, loop tensioning control, hole detection, parts counting, and similar uses (see Figure 1-1).

Emitters and receivers are available with arrays from 150 to 2400 mm (5.9" to 94.5") long. The emitter has a column of infrared light emitting diodes (LEDs) spaced 5 mm apart; their light is collimated and directed toward the receiver, positioned opposite the emitter, which has photodiodes on the same 5 mm pitch. The light from each emitter LED is detected by the corresponding receiver photodiode.

This sophisticated light curtain is capable of detecting opaque cylindrical objects as small as 5 mm in diameter or measuring part edges within 2.5 mm, depending on the scanning method selected (see Section 1.6). The sensing range is 400 mm to 4 m (16" to 13').

The EZ-ARRAY’s two-piece design makes it economical and easy to use. Controller functionality is built into the receiver housing. It can be conﬁgured for many straightforward applications simply by conﬁguring the six-position DIP switch on the front of the receiver (the receiver user interface). For more advanced control, easy-to-use PC interface software is available on the included CD to conﬁgure the sensors using a PC.

Installation is easy, too. The emitter and receiver housings can be side-mounted or end-cap-mounted using the included endcap brackets; longer models also include a center bracket (see Section 3.1).

Beam synchronization is achieved via the 8-conductor sensor cables. Individual LEDs and a 3-digit diagnostic display on the receiver provide ongoing visual sensing status and diagnostic information. Comprehensive data is available to a process controller via a combination of ﬁve outputs: two analog, two discrete, and one Modbus 485-RTU serial.

1.1 System Components

A typical A-GAGE EZ-ARRAY has four components: an emitter and a receiver, each with an integral quick-disconnect (QD) ﬁtting, plus an 8-pin QD cordset for the emitter and for the receiver (see Figure 1-2). For applications that use the Modbus RTU-485 interface, an additional 5-wire cable is used to connect the receiver with a PC or process controller, via the Modbus 485-RTU connection. (A PC used with software version 1.1 for conﬁguration must run on Windows version 1.2, when available, will be compatible with Vista

Emitter Receiver

XP or 2000; software

™

Figure 1-1. A typical A-GAGE EZ-ARRAY application

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8-Pin Euro Sensor Cordset

Optional PC for PC interface software conﬁguration

5-Pin Euro Communications Cable for use with PC; USB adapter not shown

Figure 1-2. A-GAGE EZ-ARRAY system components

P/N 130426 Rev. C 1

Overview

A-GAGE EZ-ARRAY

Instruction Manual

1.2 Features

Built-in features in the EZ-ARRAY contribute to its ease of use. Many features are available using either the user-friendly receiver interface or the more advanced PC interface.

Built-in diagnostic programming and easy-to-see indicators on the receiver simplify physical alignment and troubleshooting (Figure 1-3); more advanced diagnostics are available via the PC interface.

The receiver has a bright LED that indicates overall sensing status (OK, marginal alignment, and hardware error). Two other LEDs indicate serial communication status. Seven Zone indicators each communicate the blocked / aligned status of oneseventh of the total array. A 3-digit diagnostic display provides further diagnostic information, including number of beams blocked, whether blanking is conﬁgured, and troubleshooting codes.

The emitter has a red LED that signals proper operation (ON when power is applied). See Section 1.4 for more information about indicators and Section 4.5 for display codes and troubleshooting.

The Alignment routine (Section 4.2 or Section 5.6) automatically equalizes the excess gain of each beam for reliable object detection throughout the array. This routine need not be performed again unless the sensing application changes, or if the emitter and/or receiver is moved.

Conﬁgurable beam blanking accommodates machine components and ﬁxtures that must remain in or move through the light screen. Blanking may be set using the receiver interface, the teach wire, or the PC interface.

The EZ-ARRAY light screen provides a wide selection of sensing and output options, including measurement (“scan analysis”) modes and scanning methods that can determine a target object’s location, overall size, total height, or total width, or the number of objects. Scanning may be continuous or controlled by a gate sensor. Up to 15 systems may be networked, via Modbus; see Section 5 and Appendix A.

1.3 Configuration via DIP Switch or PC Interface

Commonly used conﬁguration options can be set up easily via a six-position DIP switch located behind a hinged clear access panel on the front of the receiver.

Access to the DIP switch can be prevented by using the screwon security plate to hold the clear access panel closed or by disabling them via the PC interface.

For more advanced, individualized applications, use the supplied PC interface software program (the “Banner Sensors GUI”; Section 5) to conﬁgure the receiver. The menu-driven program easily accesses the many scanning and output options. After the desired options are selected, the combination of selections can be saved in an .xml ﬁle, stored in the system conﬁguration computer, and recalled as needed. Communication between the

Emitter Receiver

Power ON

LED

Figure 1-3. A-GAGE EZ-ARRAY features

2 P/N 130426 Rev. C

Connection to 5-pin Communication Cable

Under Hinged Access Panel:

Zone Indicators

Beam #1 (Closest to Display)

Screw-on Security Plate limits access to DIP switch and push buttons

6-Position Conﬁguration DIP Switch

3-Digit Diagnostic Display

Alignment/Blanking Push Button

Gain (Sensitivity Adjust) Push Button

Status, Communication Active, and Communication Error LEDs

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A-GAGE EZ-ARRAY

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Overview

sensors and a PC is accomplished via the serial output and Modbus RTU-485 interface.

The software also provides alignment and diagnostics routines. An Alignment screen displays the individual status of each beam in the light screen, as well as the total number of beams, and totals of beams blocked, made, and blanked. Built-in diagnostics can be used to assess emitter and receiver status.

Outputs

In addition to the serial output (see above), all models have two analog outputs and two discrete outputs.

The analog outputs are either 4–20 mA current or 0–10V voltage, depending on model (see Section 2-1). They may be conﬁgured (via DIP switch or PC interface) for either a positive or negative slope.

Discrete output 1 is always used for measurement; discrete output 2 may be used either for alarm or measurement operation (selectable via DIP switch or PC interface). When the receiver interface is used, discrete output 1 follows the operation of analog output 1 (it conducts when the analog output senses a target is present). When the PC interface is used for conﬁguration, both discrete outputs have full conﬁgurability, including measurement mode, NPN or PNP polarity, and normally open or normally closed operation.

Display Invert

For applications where the sensors must be mounted with the display end at the top (so that the display is not right-reading), the receiver’s diagnostic display can be inverted for easy reading, either by use of the receiver’s remote wire (Section 1.5) or the PC interface.

1.4 Status Indicators

Both the emitter and receiver provide ongoing visual indication of operating and conﬁguration status.

The emitter has a red LED that signals proper operation (ON when power is applied).

into seven equal segments, each of which is represented by one of the seven LEDs. The LED closest to DIP switch S6 (see Figure 4-1) represents the group of optical channels closest to the receiver display (the “bottom” group). The LED closest to DIP switch 1 represents the far segment of channels.

These LEDs illuminate either green or red. When an LED is green, no unblanked beams are obstructed in that segment. When the LED is red, one or more beams in that segment is obstructed.

Three-Digit Display

The 3-digit display has slightly different functions during normal operation, alignment, and gain adjust modes. In normal operation the display indicates current numerical value of the measurement mode for analog output 1. The display also identiﬁes the following activated sensor functions: blanking and locked-out user interface/electronic conﬁguration, as shown in Figure 1-4. (For directions for inverting the display, see Section 1.5 or 5.8.)

During blanking mode, the display reads “n”, followed by the number of blocked beams in the array. During alignment mode, it reads “A”, followed by the number of blocked, unblanked beams; a period follows the A (“A.”) if blanking is conﬁgured.

During gain adjust mode, the display reads “

l” followed by “1” or

“2” to indicate the gain level. (A “1” represents high excess gain, and a “2” represents low contrast.)

If a sensing error occurs, the display reads “c” followed by a number that corresponds to the recommended corrective action (see Section 4.5).

Blanking Indicator

The Blanking indicator will be visible (ON) when the blanking feature is enabled. It appears as a period following the ﬁrst digit of the display.

Electronic Conﬁguration Indicator

The Electronic Conﬁguration indicator is ON when the sensor conﬁguration is deﬁned by the PC interface, and not the DIP switch and push buttons. When electronic conﬁguration is enabled, the DIP switch and push button settings are ignored.

The receiver has a bright Status LED that indicates overall sensing status (OK, marginal alignment, and hardware error). Two other LEDs indicate whether serial communication is active or if there is a communication error. Seven Zone indicators each communicate the blocked/aligned status of one-seventh of the total array. A 3-digit diagnostic display provides further diagnostic information: number of beams blocked, whether blanking is conﬁgured, and troubleshooting codes. See Section

4.5 for display codes and troubleshooting.

Zone Indicators (Beams Blocked Segment)

Seven LEDs represent emitter/receiver alignment status. They provide a visual aid for sensor alignment and monitoring objects within the sensor’s ﬁeld of view. The sensor array is partitioned

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‘A’ in this position indicates Alignment mode

Figure 1-4. Indications provided by the receiver’s 3-digit display

Period ON indicates Blanking Conﬁgured

Period ON indicates Electronic Conﬁguration Enabled

P/N 130426 Rev. C 3

Overview

TT T

T T

TT T

T T

A-GAGE EZ-ARRAY

Instruction Manual

Receiver Interface Status Indicators

The receiver has three status indicators: green/red System Status, yellow Modbus Activity, and red Modbus Error. The following table lists the indicator states.

Receiver Interface Status Indicators

LED Indicator Color Explanation

System Status Green System is OK

Red Marginal Alignment or Hardware

Error; check 3-digit display*

Modbus Activity

Modbus Error Red Communication Error: Check

* Display shows “c”: See Section 4.5.

Display shows only numbers: Low Gain/Marginal Alignment condition. See Section 4.5.

Access Alignment Mode “A” appears on 3-digit display

Yellow ON or Flashing

Process

Activity detected on the Modbus communication channel

cabling or Modbus master controller

Remote Wire Procedure

0.05 sec. ≤ T ≤ 0.8 sec.

1.5 Receiver Gray (Remote Teach) Wire

The receiver gray (remote teach) wire is used to electronically emulate the receiver push button functions (see Section 4.5) via a process controller, to disable the DIP switches for security, or to provide a gate input to initiate sensor scanning. Connect a normally open switch between the receiver’s gray wire and dc common, or connect the gray wire to a digital input (PLC) and pulse the wire as indicated in Figure 1-5.

NOTE: A low level is 0 to 2 volts and a high level is 10 to 30

volts or circuit open. Input impedance is 22kΩ.

Remote TEACH/Gate in the System Conﬁg view of the PC interface Setup screen (Section 5.8) determines the functionality of the receiver gray wire, as follows.

• Disabled: (selected via the PC interface only) the remote wire has no function (regardless of whether it is low or high).

Result

Figure 1-5. Remote wire Teach procedures

4 P/N 130426 Rev. C

Access Blanking Mode

Exit Blanking Mode

Alignment/Blanking

Exit Alignment Mode Sensor returns to run mode

Access Gain Mode

Toggle Between Gain Settings Number changes from number “1” to “2”, back to “1”, etc.

Gain Method

Save Gain Level and Exit

Invert Display

Invert

Display

Receiver Interface Enable/Disable

Enable/Disable

Receiver Interface

From Alignment Mode:

From Run Mode:

When correct level is displayed:

“n” appears on 3-digit display, along with number of blocked beams

“A.” appears on 3-digit display (sensor returns to alignment mode with blanking enabled)

“L” appears on 3-digit display, along with number “1” or “2”, to designate gain level

Gain level is conﬁgured: “1” = High-excess-gain setting “2” = Low-contrast setting Sensor returns to run mode

Display inverts from previous state; sensor continues in run mode

The factory default is Receiver Interface enabled.

Four-pulsing the remote line saves the current settings and disables the interface (the sensor continues to operate using the saved settings; changes made to the DIP switch will have no effect).

Repeating the process enables the Receiver Interface so that settings can be changed.

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A-GAGE EZ-ARRAY

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Overview

When the gray wire is disabled, the receiver is in continuous scan mode; it begins a new scan immediately after updating the outputs from the previous scan. (Continuous scan is used in most analog output applications and whenever continuous updating of the outputs is acceptable.) The gray wire is always enabled when in DIP switch mode.

• Remote Teach — The gray wire provides the full Remote Teach functionality shown in Figure 1.5.

• Alignment/Sensitivity — This mode is an abbreviated version of Remote Teach. It can perform the alignment and sensitivity adjustment functions, but not the display inversion or DIP switch enable/disable functions.

Gate Mode options can be selected via the PC interface only. The gray wire provides a gate input pulse, typically from a dc device such as an NPN-output photoelectric sensor or a PLC discrete output. Refer to Section 5 for more information.

• Gate – Active High — The receiver scans whenever the gate is pulled high.

• Gate – Active Low — The receiver scans whenever the gate is pulled low.

• Gate – Rising Edge — The receiver scans once for each lowto-high gate transition. (Multiple transitions cannot be faster than the sensor’s response for them to be reliably detected.)

• Gate – Falling Edge — The receiver scans once for each high-to-low gate transition. (Multiple transitions cannot be faster than the sensor’s response for them to be reliably detected.)

1.6 Scanning Method

One of three scanning methods may be conﬁgured:

• Straightscan

• Single-edgescan

• Double-edgescan(1,2,4,8,16,or32steps)

Straight Scan is the default mode, in which all beams are scanned in sequence, from the display end to the far end of the array. This scanning method provides the smallest object detection size. Straight scan is used when low-contrast sensitivity is selected or when single-edge and double-edge scan cannot be used. The edge resolution is 5 mm (0.2"). When low-contrast sensing is selected (used when measuring semitransparent objects), the minimum object detection size is 5 mm (0.2") diameter. When high-excess-gain sensing is selected, the minimum object detection size is 10 mm (0.4"). See Figure 1-5.

Single-Edge Scan is used to measure the height of a single object. This scanning method is commonly used for box height measurement. For single-edge scan, the receiver always activates the ﬁrst beam channel (or “bottom” beam, nearest the display). When the ﬁrst beam is blocked, the sensor performs a binary search to hunt for the last beam blocked, as follows:

1. The receiver scans only the ﬁrst beam until it is blocked (see Figure 1-7).

2. When the ﬁrst beam is blocked, the sensor looks to see whether the middle beam is blocked or made (unblocked).

3. If the middle beam is made (unblocked), the sensor checks the bottom quarter beam; if the middle beam is blocked, the sensor checks the top quarter beam.

4. The routine continues to divide the number of beams in half until the edge is found.

Single-edge scan can be used only for single, solid objects that block the ﬁrst beam (closest to the display). Because the receiver checks only the ﬁrst beam until it is blocked, single-edge scan will not function when the item to be measured does not block the ﬁrst beam. Single-edge scan is also ineffective if the object does not present a continuous blocked pattern.

Single-edge scan works only when the high-excess-gain setting is enabled. When single-edge scan is selected, the sensor object detection size is 10 mm and edge resolution is 2.5 mm.

Sensor response time is a function of sensor length and scanning method. Maximum scan times are shown in Figure 1-6.

Straight Scan

Scanning Method

Minimum Object Detection Size*

Edge Resolution

*MODS determined using a rod target object

Figure 1-6. The effect of scan mode and step size on minimum object detection size and edge resolution

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Low-

Contrast

5 mm (0.2")

High-Excess-

Gain

10 mm (0.4")

5 mm (0.2")

Single-Edge

Scan

10 mm (0.4")

2.5 mm (0.1")

1 2 4 8 16 32

10 mm (0.4")

2.5 mm (0.1")

Double-Edge Scan (per Edge)

Step Size (Number of Beams)

20 mm (0.8")

2.5 mm (0.1")

30 mm (1.2")

2.5 mm (0.1")

50 mm (2")

2.5 mm (0.1")

90 mm (3.6")

2.5 mm (0.1")

P/N 130426 Rev. C 5

170 mm (6.8")

2.5 mm (0.1")

Overview

A-GAGE EZ-ARRAY

Instruction Manual

Double-Edge Scan is used to detect two edges of a single object, for example, to determine box width measurements. Double-edge scan requires the selection of a step size: 1, 2, 4, 8, 16 or 32 beams. The sensor uses the steps to “skip” over beams, as follows:

1. The sensor activates beam 1 (closest to the sensor display end).

2. The sensor activates the next beam, determined by the step size. (For example, if the step size is 2, beam 3 is next; if the step size is 8, beam 9 is next.)

3. As long as the activated beam is made (unblocked), the sensor continues the stepping routine until a blocked beam is found.

4. When a blocked beam is found, a binary search is conducted to ﬁnd the object’s “bottom” edge.

Step #1 Step #2 Step #3

Beam #1 of 30 blocked

Beam #15 blocked

5. When the bottom edge is found, the sensor continues to step through the array until it ﬁnds the next unblocked beam.

6. Another binary search is performed to ﬁnd the second edge.

Similar to single-edge scan, double-edge scan has some restrictions: the object should provide a solid obstruction; the size of the object determines the maximum step size (Figure 1-6). Double-edge scan can be used to detect up to three objects. Like single-edge scan, double-edge scan works only when the high-excess-gain setting is selected. When doubleedge scan is selected, the sensor object detection size varies, depending on the step size, but edge resolution is 2.5 mm.

Beam #23 clear

Emitter

Receiver

Step #4 Step #5

blocked

Figure 1-7. Finding an edge using a binary search (single-edge scan)

Step #6

Beam #19 clearBeam #17

Beam #18 blocked

6 P/N 130426 Rev. C

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Overview

Maximum Scan Times (in milliseconds)

Array Length

150 mm (5.9") 2.8 1.5 3.4 2.8 2.5 2.4 1.9 N/A

300 mm (11.8") 5.0 1.5 5.9 4.1 3.2 2.8 2.3 2.1

450 mm (17.7") 7.1 1.6 8.5 5.5 4.2 4.0 3.2 2.5

600 mm (23.6") 9.3 1.6 11.0 6.8 4.9 4.2 4.0 2.8

750 mm (29.5") 11.4 1.7 13.5 8.1 5.7 4.6 4.5 4.5

900 mm (35.4") 13.6 1.7 16.0 9.5 6.1 4.7 4.6 4.6

1050 mm (41.3") 15.7 1.8 18.6 10.8 6.8 5.2 4.8 4.8

1200 mm (47.2") 17.9 1.8 21.1 12.2 7.4 5.5 4.9 4.9

1500 mm (59.1") 22.2 1.9 26.1 14.8 9.0 6.4 5.3 4.9

1800 mm (70.9") 26.5 2.0 31.2 17.5 10.5 7.3 6.0 5.6

2100 mm (82.7") 30.8 2.8 36.3 20.2 12.0 8.2 6.7 5.6

2400 mm (94.5") 35.1 2.8 41.4 22.9 13.5 9.1 7.4 5.9

NOTES: Scan times are exclusive of serial communication transmission times.

Scan times are also dependent on analog ﬁlter speed; see Section 5.8.

Figure 1-8. Maximum scan times for straight, single-edge and double-edge scanning

Straight

Scan

Single-Edge

Scan

Step

1 Beam

Step

2 Beams

Double-Edge Scan

Step

4 Beams

Step

8 Beams

Step

16 Beams

32 Beams

Step

1.7 Gain Configuration

The EZ-ARRAY provides two gain options for straight scan applications: high excess gain and low contrast. The gain method can be selected using the receiver push button, the receiver remote teach wire, or the PC interface.

High (maximized) excess gain is suited for detecting opaque objects and for reliable sensing in dirtier environments where objects to be detected are 10 mm or larger. The high excess gain method is always used in single- and double-edge scan. The high excess gain option has a minimum blocked threshold level, which provides reliable sensing at higher excess gain levels.

The low-contrast setting is used for sensing semi-transparent materials and for detecting objects as small as 5 mm (straight scan only). In low-contrast operation, only a portion of a beam must be blocked for detection to occur. In low-contrast operation, the sensor sets an individual threshold for each optical channel during the alignment process; this process equalizes the signal strength to allow semi-transparent object detection.

When using the PC interface, low-contrast sensing provides a ﬁne-tune sensitivity setting of 15% to 50%. When using the receiver interface, low-contrast sensitivity is always 30%.

Gain

Setting

Low Contrast

High Excess Gain

* MODS: Minimum Object Detection Size

Figure 1-9. Effects of Gain selection on minimum object detection

Scan Method

Straight scan 5 mm 5 mm

Single-edge scan — —

Double-edge scan — —

Straight scan 10 mm 5 mm

Single-edge scan 10 mm 2.5 mm

Double-edge scan

size and sensing resolution

EZ-ARRAY

MODS*

Depends on step size

EZ-ARRAY Resolution

2.5 mm / edge 5 mm total (both edges)

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P/N 130426 Rev. C 7

Overview

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

Receiver

Emitter

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

Receiver

Emitter

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

Receiver

Emitter

In Last Beam Blocked mode, last beam is #55 of 60

In First Beam Blocked mode, first beam is #20 of 60

In Last Beam Made mode, last beam is #50 of 60

In First Beam Made mode, first beam is #40 of 60

In Total Beams Made mode, 38 of 60 possible beams are made

In Total Beams Blocked mode, 22 of 60 possible beams are blocked

A-GAGE EZ-ARRAY

Instruction Manual

1.8 Electronic Alignment Routine

The objective of the optical alignment process is to adjust the emitter light level to maximize sensor performance. Perform the alignment procedure at installation and again whenever the emitter and/or receiver is moved.

During the alignment procedure, the receiver polls each beam channel to measure excess gain and performs a gain adjustment for each beam. When the system exits the alignment procedure, each channel’s signal strength is stored in non-volatile memory.

The procedure can be performed using the receiver remote wire, the receiver interface or the PC interface (see Section 1.5, 4.2, or 5.6). The receiver’s Alignment push button may be disabled, using the PC interface.

1.9 Blanking

If a machine ﬁxture or other equipment blocks one or more sensing beams, the affected beam channels may be blanked. The blanking option causes the receiver to ignore the status of blanked beams for measurement mode calculations. For example, if a machine ﬁxture blocks one or more beams during sensing, the output data will be incorrect; if the beams blocked by the ﬁxture are blanked, the output data will be correct. Blanking may be conﬁgured using the receiver’s Alignment push button, the receiver remote wire, or the PC interface.

“Beam Location” Modes

• First Beam Blocked (FBB): The location of the ﬁrst blocked

beam.

• First Beam Made (FBM): The location of the ﬁrst made

(unblocked) beam.

• Last Beam Blocked (LBB): The location of the last blocked

beam.

• Last Beam Made (LBM): The location of the last made beam.

• Middle Beam Blocked (MBB): The location of the beam midway

between the ﬁrst and last blocked beams.

“Beam Total” Modes

• Total Beams Blocked (TBB): The total number of blocked

beams.

• Total Beams Made (TBM): The number of beams made.

Contiguous Beams Blocked (CBB): The largest number of

•

consecutively blocked beams.

Contiguous Beams Made (CBM): The largest number of

•

consecutively made beams.

For total beam values (TBB and TBM analysis modes), selection of blanked beams affects the proportional analog outputs. Blanked beams are ignored both in the number of blocked or made beams and in the total number of beams. For example, if a 30-beam array has 10 blanked beams and 10 of the remaining 20 beams are blocked, the analog output values will be at mid-range.

1.10 Measurement Mode Selection

The outputs may be conﬁgured for any of fourteen measurement (scan analysis) modes, which refer to speciﬁc beam locations, quantities of beams, or edge transitions. Note that not all measurement mode options are available when the receiver interface is used for conﬁguration. Selected modes are individually assigned to each output (see Section 4.1 or 5.9 and 5.10).

When using the PC interface for conﬁguration, the discrete outputs can have NPN or PNP polarity (regardless of model), be normally open or normally closed, and be assigned to any of the measurement modes. When using the receiver interface, limited output conﬁguration combinations may be selected (Section 4.1).

NOTE: Array beams are numbered in sequence (beam 1 located

8 P/N 130426 Rev. C

nearest the sensor display; see Figure 1-3). The “ﬁrst beam” referenced in the following descriptions is the beam nearest the sensor display.

Figure 1-10. Measurement mode examples

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A-GAGE EZ-ARRAY

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Overview

• Transitions (TRN): The number of changes from blocked to clear status and from clear to blocked status. (If beams 6-34 are blocked, then there is a clear-to-blocked transition from beam 5 to beam 6, and a blocked-to-clear transition from beam 34 to beam 35.) Transition mode can be used to count objects within the array.

• Outside Dimension (OD): The inclusive distance (measured in beams) from the ﬁrst blocked beam to the last blocked beam.

• Inside Dimension (ID): The number of made beams, between the ﬁrst and last blocked beams.

• Contiguous First Beam Blocked (CFBB): The location of the ﬁrst blocked beam in the largest group of adjacent blocked beams.

• Contiguous Last Beam Blocked (CLBB): The location of the last blocked beam in the largest group of adjacent blocked beams.

• Carpet Nap and Carpet Edge: These measurement modes are used to measure the location of carpet backing and tuft, and are selectable only via the PC interface, and only when the Scan Type “Carpet Nap” is selected. The modes can be measured from either end of the sensor, but at least 10 beams (2") must be blocked from one edge.

• Special: This mode is reserved for specialized applications; contact the factory for information.

1.12 Discrete Output Configuration

Discrete Output 1; Receiver Interface

When the receiver interface is used for conﬁguration, the measurement mode assigned to discrete output 1 is the same as that assigned to analog output 1. When the analog output detects a target present, discrete output 1 conducts (normally open).

Discrete Output 2; Receiver Interface

Discrete output 2 (only) has two options: alarm and complementary (measurement) operation.

Alarm: Output 2 energizes when the receiver detects a sensor error (such as a disconnected cable) or whenever the excess gain of one or more beams becomes marginal.

Complementary (Measurement): Discrete output 2 operation is complementary to discrete output 1 (when output 1 is ON, output 2 is OFF, and vice versa).

Discrete Output 1 and 2 Conﬁguration; PC Interface

When the PC interface is used for conﬁguration, the discrete outputs have more options: either discrete output can be assigned to any of the measurement modes, high and low set points can be added, the outputs can be inverted, and hysteresis values can be set, as well as a scan number to smooth output performance. Discrete output 2 can be assigned to alarm mode via the PC interface also. See Section 5.9 for more information.

1.11 Analog Output Configuration

Analog output conﬁguration assigns analog outputs 1 and 2 to one of the measurement modes described in Section 1.10. When the selected measurement mode involves ﬁrst or last beam blocked or made (unblocked), the assigned output will vary in proportion to the beam number identiﬁed during a scan. When the measurement mode involves total beams blocked or made, that assigned output will vary in proportion to the total beams counted during a scan.

Analog outputs may have Null and Span values set in the PC interface, in addition to a ﬁlter setting (to smooth the output) and Zero Value (to specify the output value when the measurement mode value is zero). See Section 5.8 for more information.

1.13 Serial Communication

When the PC interface is used, the receiver communicates with a process controller via a Modbus RTU-485 interface. The PC interface software has a Communications Settings menu that includes the selected sensor communications port, options (either leave this ﬁeld set at DPB1, or change it to No Echo Suppression), and a read-only window that provides current communications status. Advanced settings are also accessible, including baud rate, timeout (in milliseconds), message delay (in milliseconds), sensor address, parity, retry and byte delay. See Section 5.10 and the Appendix for more information.

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P/N 130426 Rev. C 9

Components and Specifications

2. Components and Specifications

2.1 Sensor Models

A-GAGE EZ-ARRAY

Instruction Manual

Emitter/Receiver Model

NPN Outputs

EA5E150Q Emitter EA5R150NIXMODQ Receiver EA5R150NUXMODQ Receiver

EA5E300Q Emitter EA5R300NIXMODQ Receiver EA5R300NUXMODQ Receiver

EA5E450Q Emitter EA5R450NIXMODQ Receiver EA5R450NUXMODQ Receiver

EA5E600Q Emitter EA5R600NIXMODQ Receiver EA5R600NUXMODQ Receiver

EA5E750Q Emitter EA5R750NIXMODQ Receiver EA5R750NUXMODQ Receiver

EA5E900Q Emitter EA5R900NIXMODQ Receiver EA5R900NUXMODQ Receiver

EA5E1050Q Emitter EA5R1050NIXMODQ Receiver EA5R1050NUXMODQ Receiver

EA5E1200Q Emitter EA5R1200NIXMODQ Receiver EA5R1200NUXMODQ Receiver

EA5E1500Q Emitter EA5R1500NIXMODQ Receiver EA5R1500NUXMODQ Receiver

EA5E1800Q Emitter EA5R1800NIXMODQ Receiver EA5R1800NUXMODQ Receiver

EA5E2100Q Emitter EA5R2100NIXMODQ Receiver EA5R2100NUXMODQ Receiver

EA5E2400Q Emitter EA5R2400NIXMODQ Receiver EA5R2400NUXMODQ Receiver

* Models with array lengths 1050 mm and longer ship with a center bracket as well as two end-cap brackets.

Emitter/Receiver Model

PNP Outputs

EA5E150Q Emitter EA5R150PIXMODQ Receiver EA5R150PUXMODQ Receiver

EA5E300Q Emitter EA5R300PIXMODQ Receiver EA5R300PUXMODQ Receiver

EA5E450Q Emitter EA5R450PIXMODQ Receiver EA5R450PUXMODQ Receiver

EA5E600Q Emitter EA5R600PIXMODQ Receiver EA5R600PUXMODQ Receiver

EA5E750Q Emitter EA5R750PIXMODQ Receiver EA5R750PUXMODQ Receiver

EA5E900Q Emitter EA5R900PIXMODQ Receiver EA5R900PUXMODQ Receiver

EA5E1050Q Emitter EA5R1050PIXMODQ Receiver EA5R1050PUXMODQ Receiver

EA5E1200Q Emitter EA5R1200PIXMODQ Receiver EA5R1200PUXMODQ Receiver

EA5E1500Q Emitter EA5R1500PIXMODQ Receiver EA5R1500PUXMODQ Receiver

EA5E1800Q Emitter EA5R1800PIXMODQ Receiver EA5R1800PUXMODQ Receiver

EA5E2100Q Emitter EA5R2100PIXMODQ Receiver EA5R2100PUXMODQ Receiver

EA5E2400Q Emitter EA5R2400PIXMODQ Receiver EA5R2400PUXMODQ Receiver

Analog Output

– Current (4–20 mA) Voltage (0–10V)

Array

Length

150 mm (5.9")

300 mm (11.8")

450 mm (17.7")

600 mm (23.6")

750 mm (29.5")

900 mm (35.4")

1050 mm (41.3")*

1200 mm (47.2")*

1500 mm (59.1")*

1800 mm (70.9")*

2100 mm (82.7")*

2400 mm (94.5")*

Total

Beams

120

150

180

210

240

300

360

420

480

Emitter

Receiver

10 P/N 130426 Rev. C

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A-GAGE EZ-ARRAY

22.5 mm (0.88")

72.5 mm (2.85 ")

70.0 mm (2.75")

82.0 mm (3.23")

77.5 mm (3.05")

White

Brown

Blue

Gray

Black

Green

Yellow

Gray

Red

Brown

White

Blue

Pink

Ø15.0 mm

(0.59")

M12X1

48.5 mm (1.91")

M12X1

Ø14.5 mm

(0.57")

40.0 mm (1.57")

31.8 mm (1.25")

31 mm (1.22")

M12X1

Ø13.5 mm

(0.53")

Instruction Manual

2.2 Cordsets and Connections

Quick-Disconnect Sensor Cordsets

Model Description Pinout

MAQDC-815

Straight female

MAQDC-830

MAQDC-850

Communication Connections

Model Description Pinout

Communications Cables

MQDMC-506

MQDMC-515

MQDMC-530

connector, 8-pin Euro-style

Straight male connector, 5-pin Euro-style

5 m (15') long

9 m (30') long

15 m (50') long

2 m (6.5') long

5 m (15') long

9 m (30') long

Components and Specifications

Female Connector Shown

Male Connector Shown

MQDMC-506RA

MQDMC-515RA

Right-angle male connector, 5-pin

2 m (6.5') long

5 m (15') long

Euro-style

MQDMC-530RA

9 m (30') long

USB Serial Adapter Dimensions

INTUSB485-1

For connection of 5-pin communications cable to computer USB port

2.3 Alignment Aids

Model Description

LAT-1-SS

Self-contained visible-beam laser tool for aligning any EZ-ARRAY emitter/ receiver pair. Includes retroreﬂective target material and mounting clip.

EZA-LAT-SS Replacement adaptor (clip) hardware for EZ-ARRAY models

EZA-LAT-2 Clip-on retroreﬂective LAT target

BRT-THG-2-100 2" retroreﬂective tape, 100'

BT-1 Beam Tracker

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LAT-1-SS

P/N 130426 Rev. C 11

Components and Specifications

50.0 mm (1.97")

58.2 mm (2.29")

39.2 mm (1.54")

4.2 mm (0.17")

44.4 mm (1.75")

20 mm (0.79")

40 mm (1.57")

(4) M10 Bolt

Pole 40 mm (1.58") Square

Usable

Stand

Height

Base

6.4 mm (0.25")

120.6 mm (4.75")

2.4 Accessory Mounting Brackets and Stands

See Section 2.5 for standard brackets. Order one EZA-MBK-20 bracket per sensor, two per pair.

Model Description

Universal adaptor bracket pair

EZA-MBK-20

for mounting to engineered / slotted aluminum framing

™

(e.g., 80/20

, Unistrut™).

A-GAGE EZ-ARRAY

Instruction Manual

EZA-MBK-20

MSA Series Stands (Base Included)*

Stand Model

MSA-S24-1

MSA-S42-1

MSA-S66-1

MSA-S84-1

* Available without a base by adding sufﬁx “NB” to the model number, e.g.,

MSA-S24-1NB.

Useable Stand

Height

Overall Stand

Height

483 mm (19") 610 mm (24")

940 mm (37") 1067 mm (42")

1549 mm (61") 1676 mm (66")

2007 mm (79") 2134 mm (84")

2.5 Replacement Parts

Description Model

Access cover with label – receiver EA5-ADR-1

Access cover security plate (includes 2 screws, wrench)

Wrench, security EZA-HK-1

Standard bracket kit with

Black EZA-MBK-11

hardware (includes 2 end brackets and hardware to mount to MSA Series stands)

Stainless Steel

Center bracket kit (includes 1 bracket and hardware to mount to MSA Series stands)

EZA-TP-1

EZA-MBK-11N

EZA-MBK-12

NOTE: Standard brackets shipped with sensors connect directly to

MSA series stands, using hardware included with the stands.

2.6 Specifications

Emitter/Receiver Range

Field of View

Beam Spacing

Light Source

Minimum Object Detection Size

Sensor Positional Resolution

12 P/N 130426 Rev. C

400 mm to 4 m (16" to 13')

Nominally ± 3°

5 mm (0.2")

Infrared LED

Straight Scan, Low-Contrast: 5 mm (0.2") Straight Scan, High-Excess-Gain: 10 mm (0.4")

See Figure 1-5 for other scan mode values; size is tested using a rod.

Straight Scan: 5 mm (0.2") Double-Edge Scan: 2.5 mm (0.1") Single-Edge Scan: 2.5 mm (0.1")

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A-GAGE EZ-ARRAY

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2.6 Specifications, continued

Components and Specifications

Supply Voltage (Limit Values)

Supply Power Requirements

Teach Input (Receiver Gray Wire)

Two Discrete Outputs

Two Analog Outputs

Serial Communication Interface (also see Appendix A)

Scan Time

Status Indicators (also see Section 1.4)

Emitter: 12 to 30V dc Receiver Analog Current Models: 12 to 30V dc Receiver Analog Voltage Models: 15 to 30V dc

Emitter/Receiver Pair (Exclusive of Discrete Load): Less than 9 watts

Power-up delay: 2 seconds

Low: 0 to 2 volts High: 6 to 30 volts or open (input impedance 22 K ohms)

Solid-State NPN or PNP (current sinking or sourcing)

Rating: 100 mA maximum each output OFF-State Leakage Current:

ON-State Saturation Voltage:

Protected against false pulse on power-up and continuous overload or short circuit.

Voltage Sourcing: 0 to 10V (maximum current load of 5 mA) Current Sourcing: 4 to 20 mA (maximum resistance load = (V

EIA-485 Modbus RTU (up to 15 nodes per communication ring) RTU binary format Baud Rate: 9600, 19.2K or 38.4K 8 Data Bits, 1 Stop Bit, and Even, Odd, or 2 Stop Bits and No Parity

Scan times depend on scan mode and sensor length. Straight scan times range from 2.8 to 26.5 ms. See Figure 1-8 for all combinations.

Emitter:

R ed Status LED

ON Red — Status OK Flashing at 1 hz — Error

NPN: less than 200 uA @ 30V dc

PNP: less than 10 uA @ 30V dc NPN: less than 1.6V @ 100 mA

PNP: less than 2.0V @ 100 mA

−3) / 0.020)

supply

Receiver: 7 Zone Indicators

Red — Blocked channels within zone

Green — All channels clear within zone 3- digit 7-segment measurement mode / diagnostic indicator Se nsor Status Bi-Color Indicator LED

Red — Hardware Error or Marginal Alignment

Green — OK Modbus Activity Indicator LED: Yellow Modbus Error Indicator LED: Red

System Configuration (Receiver Interface)

System Configuration (PC interface)

Connections

Construction

Environmental Rating

Operating Conditions

Certifications

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6-position DIP switch: Used to set scanning type, measurement modes, analog slope, and discrete output 2 function (see Section 4.1).

Push Buttons: Two momentary push buttons for alignment and gain level selection.

Supplied software provides all conﬁguration options of receiver interface, plus additional functionality; see Sections 1 and 5.

Serial communication: The receiver uses a PVC-jacketed, 5-conductor 22-gauge quick-disconnect cable, 5.4 mm diameter; see Sections 2.2 and 5.2. Other Sensor connections: 8-conductor quick-disconnect cables (one each for emitter and receiver), ordered separately; see Section 2.2 for available lengths (may not exceed 75 meters long), PVCjacketed cables measure 5.8 mm diameter, have shield wire; 22-gauge conductors.

Aluminum housing with clear-anodized ﬁnish; acrylic lens cover

IEC IP65

Temperature: −40° to +70° C (−40° to 158° F) Maximum relative humidity: 95% at 50° C (non-condensing)

P/N 130426 Rev. C 13

+ 33 hidden pages

Banner EZ-ARRAY USB Serial Adapter User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual