Banner iVu Plus TG Gen2, iVu PLUS TG Instruction Manual

iVu Plus TG Gen2 Image Sensor

179042

Instruction Manual

Original Instructions
179042 Rev. C
21 April 2015

iVu Plus TG Gen2 Image Sensor

Contents

1 Overview of the Sensor

...................................................................................................5

2 Installation .....................................................................................................................6

2.1 Components .............................................................................................................................6

2.1.1 iVu with Integrated Display ...............................................................................................6

2.1.2 iVu with Remote Display ...................................................................................................6

2.2 Installing and Connecting the Sensor ..........................................................................................7

2.2.1 Cable Connections for Integrated Display ...........................................................................8

2.2.2 Cable Connections for Remote Display ...............................................................................8

2.2.3 Installing a Filter on iVu Series Sensors ..............................................................................9

2.3 iVu Trigger, Remote Teach, and I/O Waveforms ......................................................................... 10

2.3.1 PNP (Low-to-High) Trigger and Remote Teach Input Waveforms .......................................... 11

2.3.2 NPN (High-to-Low) Trigger and Remote Teach Input Waveforms ..........................................11

2.3.3 iVu Output Waveforms .................................................................................................. 12

3 Major Features .............................................................................................................14

3.1 Demo Mode ............................................................................................................................14

3.2 Sensor Types ..........................................................................................................................14

3.2.1 Area Sensor .................................................................................................................14

3.2.2 Blemish Sensor ............................................................................................................ 15

3.2.3 Match Sensor ...............................................................................................................15

3.2.4 Sort Sensor ................................................................................................................. 15

3.3 Multiple Sensors .....................................................................................................................15

3.4 Multiple Inspections ................................................................................................................15

3.4.1 Adding a New Inspection ............................................................................................... 15

3.4.2 Changing Running Inspections ........................................................................................16

3.5 Imager Resolution ..................................................................................................................16

3.6 iVu Plus Communication Summary of Ethernet and Serial ............................................................ 16

3.6.1 Communication Channels ...............................................................................................17

3.7 Trigger Modes ........................................................................................................................17

3.8 Mask .................................................................................................................................... 18

4 Home Screen ................................................................................................................ 19

4.1 Display Mode .........................................................................................................................19

4.1.1 Image with Annotations .................................................................................................19

4.1.2 Image without Annotations ............................................................................................ 20

4.1.3 Inspection Statistics .......................................................................................................20

5 Main Menu Reference ....................................................................................................22

5.1 Main Menu .............................................................................................................................22

5.1.1 Icon Reference ..............................................................................................................23

5.2 Inspection Menu ......................................................................................................................24

5.2.1 Sensors Menu .............................................................................................................. 25

5.2.2 Motion Menu .................................................................................................................29

5.2.3 Properties Menu ........................................................................................................... 30

5.2.4 Stored Inspections .........................................................................................................30

5.3 Imager Menu ..........................................................................................................................32

5.3.1 Auto Exposure ...............................................................................................................32

5.3.2 Exposure ......................................................................................................................32

5.3.3 Gain ............................................................................................................................ 33

5.3.4 Trigger .........................................................................................................................33

5.3.5 Focus ...........................................................................................................................34

5.3.6 Strobe ..........................................................................................................................34

5.3.7 FOV (Field of View) ........................................................................................................35

5.3.8 Resolution ................................................................................................................... 36

5.4 System Menu ..........................................................................................................................37

5.4.1 Mode ........................................................................................................................... 37

5.4.2 System Configuration .....................................................................................................38

5.4.3 System Information ....................................................................................................... 39

5.4.4 Lock Device ................................................................................................................. 39

5.4.5 Communications ............................................................................................................39

5.4.6 Discrete I/O ..................................................................................................................48

5.4.7 Display Settings ............................................................................................................ 50

5.4.8 Reboot Sensor ...............................................................................................................51

5.4.9 Firmware Update ...........................................................................................................51

5.5 Logs Menu ..............................................................................................................................52

5.5.1 Inspection Logs .............................................................................................................52

5.5.2 System Logs .................................................................................................................53

iVu Plus TG Gen2 Image Sensor

5.5.3 Communication Logs ......................................................................................................54

6 Setting up an Inspection

6.1 Acquiring a Good Image ...........................................................................................................56

6.1.1 Adjust the Focus on a Micro Video Lens Model .................................................................. 57

6.1.2 Adjust the Focus on a C-Mount Lens Model .......................................................................57

6.2 Using iVu Gen1 and Gen2 Devices in the Same Application ........................................................... 58

...............................................................................................56

7 Configuring Sensors .....................................................................................................59

7.1 Sensor Configuration Shortcut Menu ......................................................................................... 59

7.2 Configuring an Area Sensor ...................................................................................................... 61

7.3 Configuring a Blemish Sensor ....................................................................................................64

7.4 Configuring a Match Sensor ...................................................................................................... 67

7.4.1 Remote Teach ...............................................................................................................70

7.5 Configuring a Sort Application ...................................................................................................71

7.6 Configuring Motion ................................................................................................................. 72

7.6.1 Number of Edges ...........................................................................................................73

7.6.2 Sensitivity .................................................................................................................... 73

7.6.3 Rotation ....................................................................................................................... 73

7.7 Configuring Multiple Sensors in the Inspection ............................................................................73

7.8 Configuring a Mask .................................................................................................................75

8 Communications Guide ................................................................................................ 76

8.1 iVu Plus Communication Summary of Ethernet and Serial ............................................................ 76

8.1.1 Communication Channels ...............................................................................................76

8.1.2 Industrial Ethernet ........................................................................................................76

8.1.3 Command Channel .........................................................................................................76

8.1.4 Data Export .................................................................................................................. 77

8.1.5 Image Export ...............................................................................................................78

8.2 Enabling Communications ........................................................................................................79

8.2.1 Setting Up Ethernet Communications ...............................................................................79

8.2.2 Setting Up Serial Communications ................................................................................... 83

8.3 Testing and Troubleshooting iVu Plus Communications ................................................................. 86

8.3.1 Understanding the Communication Log .............................................................................86

8.3.2 Ethernet I/O ................................................................................................................ 87

8.3.3 Serial I/O .................................................................................................................... 87

8.4 Command Channel Primer ....................................................................................................... 89

8.4.1 Command Channel Commands ........................................................................................89

8.4.2 Conventions Used for Examples .......................................................................................90

8.4.3 Examples .....................................................................................................................90

8.4.4 Command Channel Reference .........................................................................................91

8.4.5 Multiple Sensors Inspection ............................................................................................97

8.4.6 Command Channel Command Status Register ................................................................... 98

8.4.7 Command Channel Error Codes ....................................................................................... 98

8.5 iVu Discovery Protocol ............................................................................................................. 99

8.5.1 Overview .....................................................................................................................99

8.5.2 UDP Usage ...................................................................................................................99

8.5.3 Packet Format ..............................................................................................................99

8.5.4 Message Flow .............................................................................................................103

9 Industrial Ethernet Overview .....................................................................................107

9.1 Device Setup ....................................................................................................................... 107

9.1.1 Set IP Address ............................................................................................................107

9.1.2 Set Industrial Ethernet Protocol (EIP/Modbus/TCP/PCCC/PROFINET®) ................................107

9.1.3 Set Trigger Mode ........................................................................................................ 107

9.2 Supported Functions .............................................................................................................. 107

9.2.1 iVu Input Values .......................................................................................................... 107

9.2.2 iVu Output Values ........................................................................................................108

9.3 Sensor Operation ...................................................................................................................108

9.3.1 General Command Execution ........................................................................................109

9.4 EtherNet/IP .......................................................................................................................... 109

9.4.1 Inputs to iVu (Outputs from PLC) ...................................................................................110

9.4.2 Outputs from the iVu (Inputs to the PLC) ........................................................................ 110

9.4.3 Multiple Sensors Mapping Options .................................................................................. 111

9.4.4 Input and Output Flags Bits ...........................................................................................115

9.4.5 Configuration Assembly Object ...................................................................................... 116

9.4.6 Data Formats .............................................................................................................. 116

9.4.7 Minimum Requested Packet Inverval (RPI) Value .............................................................116

9.4.8 iVu Plus EDS File Installation in ControlLogix Software ...................................................... 116

9.4.9 RSLogix5000 Configuration ........................................................................................... 123

9.5 Modbus/TCP ..........................................................................................................................129

9.5.1 iVu Plus Input Values ....................................................................................................131

9.5.2 iVu Plus Output Values ..................................................................................................131

9.5.3 Multiple Sensors Mapping Options .................................................................................. 131

iVu Plus TG Gen2 Image Sensor

9.5.4 Flags ..........................................................................................................................136

9.6 PLC5 and SLC 5 (PCCC)

9.6.1 Configuration ............................................................................................................. 137

9.6.2 Inputs to iVu (Outputs from PLC) ...................................................................................139

9.6.3 Outputs from iVu (Inputs to PLC) ...................................................................................139

9.6.4 Multiple Sensors Mapping Options .................................................................................. 139

9.6.5 Input and Output Flags .................................................................................................144

9.7 PROFINET .............................................................................................................................144

9.7.1 General Station Description (GSD) File ............................................................................144

9.7.2 iVu PROFINET IO Data Model .........................................................................................145

9.7.3 Configuration Instructions ............................................................................................157

9.8 Sample Timing Diagram ........................................................................................................ 179

9.9 Command Channel Command Status Register ........................................................................... 182

9.10 Diagnostic Guide ..................................................................................................................182

9.10.1 Ethernet Diagnostics ..................................................................................................182

9.10.2 Networking and TCP/IP Diagnostics ............................................................................. 183

9.10.3 Industrial Protocols Troubleshooting ............................................................................ 185

9.11 Additional Information .........................................................................................................193

9.11.1 iVu Command Channel Commands (iVu Command Channel over Industrial EtherNet) ..........193

..........................................................................................................137

10 Debugging Inspections ............................................................................................ 198

10.1 iVu Emulator .......................................................................................................................198

10.2 How to Round-Trip Debug Using the Emulator ......................................................................... 198

10.2.1 How to Debug Using the Emulator from a PC ..................................................................198

10.2.2 How to Debug Using the Emulator from the USB Flash Drive ........................................... 199

11 Updating the Sensor ................................................................................................ 200

11.1 Update Process ....................................................................................................................200

11.2 How to Set or Modify a Device Name using the Emulator ...........................................................200

11.3 How to Reset the Sensor Password .........................................................................................201

11.4 How to Use Bitmap Image Files with the iVu Emulator .............................................................. 201

12 LED Indicator Troubleshooting ................................................................................. 203

12.1 Errors .................................................................................................................................203

12.2 Warnings ............................................................................................................................203

13 Product Support and Maintenance ............................................................................ 204

13.1 Product Support .................................................................................................................. 204

13.2 Maintenance ....................................................................................................................... 204

13.3 Contact Us .........................................................................................................................205

13.4 Banner Engineering Corp Limited Warranty ............................................................................ 206

iVu Plus TG Gen2 Image Sensor

1 Overview of the Sensor

iVu Plus TG Gen2 Series Sensor sensor is used to monitor parts for type, size, orientation, shape, and location. No PC

The
is required to configure the sensor. Instead, the sensor has a color touch screen display (either integrated with the sensor
or available as a remote display) that you can use to set up and monitor inspections. The following features are available:

• Self-contained image sensor; no PC required

• Easy configuration: install/connect iVu, select sensor type, acquire image, set inspection parameters

• Intuitive interface and sophisticated features make powerful inspection capabilities simple

• Multiple sensor configuration

• GUI available in multiple languages (English, French, German, Italian, Spanish, Japanese, Simplified Chinese,
Portuguese, and Turkish)

• 68.5 mm (2.7 in) touch-screen LCD display or separate touch screen display that mounts remotely from the sensor
to allow easy access to the user interface and to view inspection images

• Four sensor types in one package—a match sensor that determines whether a pattern on a label or part matches a
reference pattern; a sort sensor that can recognize and sort up to ten different patterns within the same
inspection; an area sensor that detects whether or not a particular feature (or features) is present; and a blemish
sensor that detects flaws on parts

• Robust IP67 housing with integrated lighting (red, blue, green, or infrared)

• M12 connector with 10 to 30 V dc for power supply and PNP or NPN output

• External trigger input, remote TEACH input, and external strobe output available

• USB port for uploading and downloading of inspections and log files for easy updating and diagnostics

• Software emulator for PC available to evaluate inspections offline based on bitmap images or inspection logs

www.bannerengineering.com - Tel: [phone]

C

A B

iVu Plus TG Gen2 Image Sensor

2 Installation

2.1 Components

2.1.1 iVu with Integrated Display

The iVu Series sensor comes fully assembled with the lens and an integrated ring light if so ordered. The integrated
touchscreen display has a plastic cover to protect the display. Remove this cover when setting up the sensor. When the
display is not in use be sure to keep the display covered to protect it.

If an integrated ring light is not used, another light source is needed. Various lights are available from Banner. Operating
in external trigger mode requires a triggering source (for example, the Banner WORLD-BEAM® QS18VN6D sensor).

1 LED - Green: Ready; Red: Error
2 LED - Green: Pass; Red: Fail
3 Ethernet I/O LED
4 Focusing Window
5 Focusing Window Locking Clip
6 Integrated Display

A 8-pin Euro-style (M12) female USB Cable Connector
B I/O Cable Connector
C 12-pin Euro-style (M12) male Power and I/O Cable Connector

Mounting Bracket Mounting Holes (uses supplied three M4 x 4 mm screws)

2.1.2 iVu with Remote Display

The iVu sensor for use with a Remote Display comes fully assembled with the lens and an integrated ring light if so
ordered. Although the Remote Display is not required for normal sensor operation, it is needed to set up the sensor and to
monitor inspections.

If an integrated ring light is not used, another light source is needed. Various lights are available from Banner. Operating
in external trigger mode requires a triggering source (for example, the Banner WORLD-BEAM® QS18VN6D sensor).

6 www.bannerengineering.com - Tel: [phone]

A

B

C D

iVu Plus TG Gen2 Image Sensor

1 LED - Green: Ready; Red: Error
2 LED - Green: Pass; Red: Fail
3 Ethernet I/O LED
4 Focusing Window
5 Focusing Window Locking Clip

A Remote Display connector
B Power and I/O Cable connector
C USB connector
D Ethernet connector

Mounting Bracket Mounting Holes (uses supplied three M4 x 4 mm screws)

2.2 Installing and Connecting the Sensor

The iVu Plus TG sensor requires a bracket for mounting. Three brackets are available from Banner. The brackets allow the
sensor to be mounted either perpendicular to the part or at an adjustable angle.

Thread three M4 x 4mm screws through the bracket into the mounting holes in the bottom of the sensor. Tighten all three
screws.

Table 1: iVu Brackets

SMBIVURAL SMBIVURAR SMBIVUU

www.bannerengineering.com - Tel: [phone]

C

A B

A

B

C D

iVu Plus TG Gen2 Image Sensor

2.2.1 Cable Connections for Integrated Display

The cable connections on the iVu Plus with integrated display are shown below, and power I/O connections (C) are defined
in the Power I/O Connections

Pin # Wire Color Description Direction

1 White Output 1 Output
2 Brown 10-30V dc Input
3 Green Output 2 Output
4 Yellow Strobe Out (5V dc only) Output
5 Gray Remote Teach Input
6 Pink External Trigger Input
7 Blue Common (Signal Ground) Input
8 Red Ready Output

9 Orange Output 3 Output
10 Light Blue RS-232 TX Output
11 Black RS-232 Signal Ground Output
12 Violet RS-232 Rx Input

table below.

A USB Connector
B Ethernet Connector
C Power I/O Connector

NOTE: Micro video lens model shown, C-Mount model

connections are identical.

Power I/O Connections

2.2.2 Cable Connections for Remote Display

The cable connections on the iVu Plus with remote display are shown below, and power I/O connections (B) are defined in
the Power I/O Connections table below.

Pin # Wire Color Description Direction

1 White Output 1 Output

2 Brown 10-30V dc Input

8 www.bannerengineering.com - Tel: [phone]

A Remote Display Connector
B Power I/O Connector
C USB Connector
D Ethernet Connector

NOTE: Micro video lens model shown, C-Mount model

connections are identical.

Power I/O Connections

iVu Plus TG Gen2 Image Sensor

Power I/O Connections

Pin # Wire Color Description Direction

3 Green Output 2 Output

4 Yellow Strobe Out (5V dc only) Output

5 Gray Remote Teach Input

6 Pink External Trigger Input

7 Blue Common (Signal Ground) Input

8 Red Ready Output

9 Orange Output 3 Output
10 Light Blue RS-232 TX Output
11 Black RS-232 Signal Ground Output
12 Violet RS-232 Rx Input

2.2.3 Installing a Filter on iVu Series Sensors

Installing a Filter on the Micro Video Lens Model

To install a filter on the iVu Series sensor with Micro Video Lens, use the illustration as a guide and follow the steps listed
below.

CAUTION: Failure to follow these instructions may cause damage to your iVu Series sensor.

Micro Video Lens Models

A Lens
B Focusing Window
C Locking Clip
D Locking Screw
E Filter Cap
F Filter

1. Remove the Focusing Window locking screw (D) using the 1/16 in. hex key.

NOTE: The Locking Clip (C) inserts in a groove near the top of the Focusing Window (B). When
removing the window, the Locking Clip will be loose. Be careful not to lose the clip while
removing the window.

2. Unscrew the Focusing Window by turning it clockwise approximately 5 complete turns or until the Focusing Window
disengages from the light/lens assembly.

NOTE: The light/lens assembly may include an integrated ring light or a blank disk if an
integrated ring light is not used. Be careful that the light/lens assembly does not pull out when
removing the Focusing Window. Give a slight tug on the Focusing Window when you think
you've unscrewed it far enough. If the lens assembly moves with the window, continue to rotate
the window clockwise until the lens assembly does not move.

3. Set the Focusing Window aside. Be careful not to get any debris on the window's O-ring.
If present, remove the protective covering on the filter.

4.

5. Place the filter into the Filter Cap and press the cap onto the lens.

www.bannerengineering.com - Tel: [phone]

C

B

Groove

D

C

A

B

E

C

iVu Plus TG Gen2 Image Sensor

6. After the filter is installed, place the Focusing Window back into the housing while inserting the Locking Clip into
the groove as shown.

7.

Press the Focusing Window onto the housing to make sure that it seats correctly (no gap between the window and
housing). Rotate the window counter-clockwise at least two turns.

8. Replace the locking tab screw but do not tighten until you have set up and focused the sensor again.

Installing a Filter on the C-Mount Lens Model

To install a filter on the iVu Series sensor with C-Mount Lens, use the illustration as a guide and follow the steps listed
below.

CAUTION: Failure to follow these instructions may cause damage to your iVu Series sensor.

C-Mount Lens Models

A C-Mount Lens
B Lens Enclosure
C Retainer Ring (optional)
D Filter (optional)
E Filter Retainer Ring Tool

NOTE: Filter Kits are available separately.

1. Remove the Lens Enclosure and Lens.

2.

Install filter behind the retainer ring. Make sure it is fully seated.

3. Using the provided retainer ring tool, thread the retainer ring into the sensor until it firmly seats the filter.

4. Replace the Lens and Lens Enclosure on the camera.

CAUTION: Electrostatic Discharge
Avoid the damage that electrostatic discharge (ESD) can cause to the Sensor.

Always use a proven method for preventing electrostatic discharge when installing a lens or attaching a
cable.

2.3 iVu Trigger, Remote Teach, and I/O Waveforms

The iVu has two input signals—Trigger and Remote Teach. The default setting is to detect the low to high transition. This
setting can be changed in the Main Menu > System > Discrete I/O > Input Polarity screen on the sensor.

10 www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

2.3.1 PNP (Low-to-High) Trigger and Remote Teach Input Waveforms

Power up

Wire Color

Pink

Gray

Function

Trigger

Remote

T

each

The sensor triggers from low to high, and Remote Teach behaves electrically like trigger.

NOTE:

Table 2: Required iVu Input Signal Voltage

ON OFF

PNP +10 to 30 V dc < 2 V dc

2.3.2 NPN (High-to-Low) Trigger and Remote Teach Input Waveforms

Power up

Wire Color

Pink

Gray

Function

Trigger

Remote

each

T

The sensor triggers from high to low, and Remote Teach behaves electrically like trigger.

NOTE:

Table 3: Required iVu Input Signal Voltage

ON OFF

NPN < 2 V dc +10 to 30 V dc

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

NOTE: If the device used to trigger or remote teach the
options regarding the use of a pull-up resistor:

Option 1: Put a pull-up resistor, rated approximately 1k ohm, between the sensor's positive (+)
voltage and the sensor's input as shown below.

Option 2: Enable the Input Pullup in the iVu Plus TG software (Main Menu > System > Discrete I/O
> Input Pullup).

2.3.3 iVu Output Waveforms

Sinking

Pullup Resistor

NPN

VCC

1k ohm

iVu Plus TG is a sinking device, these are the

iVu

Trigger Input

Remote Teach Input

Function

Ready

Outputs 1,2, and 3

(Set as Active Pass)

Outputs 1, 2, and 3

(Set as Active Fail)

Strobe Out

(Configure as External

& Expose Based)

Function

Ready

Outputs 1, 2, and 3

(Set as Active Pass)

Outputs 1, 2, and 3

(Set as Active Fail)

(Pass) (Fail) (Pass)

(Pass)

(Fail)

(Pass)

Figure 1. PNP Outputs

(Pass) (Fail) (Pass)

(Pass)

(Fail)

(Pass)

Strobe Out

(Configure as External

& Expose Based)

12 www.bannerengineering.com - Tel: [phone]

Figure 2. NPN Outputs

iVu Plus TG Gen2 Image Sensor

NOTE:

Table 4: Expected iVu Output Signal Voltage

ON OFF

PNP + V 0 V
NPN +1 V +V

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

3 Major Features

3.1 Demo Mode

The first time you power up the iVu Plus TG sensor, it starts in Demo Mode and allows you to choose whether to stay in
Demo Mode or exit to Live Mode
sensor is set up without having to worry about focus, lighting, or triggers. In this mode, you can learn how to make
adjustments while working with the different sensor types and observing how the adjustments affect the sensor results.
When you exit Demo Mode, the sensor reboots into its normal operating mode with default settings.

NOTE: Switch between Live Mode and Demo Mode any time by going to Main Menu > System >
Mode.

. Demo Mode uses stored images and inspection parameters that demonstrate how the

3.2 Sensor Types

The iVu Plus TG sensor includes four Sensor Types:

Area Sensor

•

• Blemish Sensor

• Match Sensor

• Sort Sensor

3.2.1 Area Sensor

An Area type sensor is used to ensure that a feature, or multiple features, are present on a part. When setting up the
sensor for an Area inspection, a feature, such as a drilled hole, is identified as well as the size (area) expected. If there is
more than one of the identified features on a part, the number expected can be set as well. During the inspection, the
sensor verifies that each part or package includes the specified number of features. Some example applications include:

• Inspections that check for drilled holes on a part

• Inspections that check for correctly stamped parts

• Inspections that ensure proper packaging (for example, check that a packing slip exists in or on a box; test
whether a vial is properly capped)

• Inspections of blister packs

14 www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

3.2.2 Blemish Sensor

A Blemish type sensor can be used to find flaws on a part (for example, scratches on a disc), or it can be used to make
sure a feature exists on a part. Although verifying a feature is present on a part is more commonly an Area sensor
application, a Blemish sensor may be a better option when dealing with variable materials or uneven lighting. Some
example applications include:

•

Inspections that check for scratches on a part, and reject parts where the scratches are too numerous or larger
than acceptable

• Inspections that check for the presence of some label or marking on a part that may vary in color

3.2.3 Match Sensor

A Match type sensor is used to verify that a pattern, shape, or part in any orientation matches a reference pattern. The
reference pattern is taught during setup. A reference pattern might include alphanumeric characters, logos, or any other
shapes. During an inspection, the sensor checks that each part or package being inspected matches the reference pattern.
Additionally, if there is more than one of the identified pattern, the number expected can be set.

Some example applications include:

• Date/Lot code inspections

• Label inspections

• Part etching inspections

• Part orientation inspections

• Part shape inspections

3.2.4 Sort Sensor

A Sort sensor type that can recognize and sort up to ten different patterns within the same inspection. Each reference
pattern is taught during setup and stored in one of ten pattern memory locations. A reference pattern might include
alphanumeric characters, logos, or any other shapes, and the pass criteria can be set for any or all of the patterns.

Some example application include:

• Identify and sort parts on a production line

• Ensure that several different parts are present in a package

3.3 Multiple Sensors

Firmware versions 1.2.0 and newer include multiple sensor functionality. Each part inspected can now use multiple sensors
to inspect more than one feature. Up to 30 such inspections can be created and stored on the device.

3.4 Multiple Inspections

The iVu Plus supports multiple inspections that facilitate storing and controlling up to 30 inspections of different Sensor
Types.

3.4.1 Adding a New Inspection

To Add a new stored inspection:

1.

Go to Main Menu > Inspection > Stored Inspections and click Add New.

2.

Select the Sensor Type for the new inspection, and click Next.

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

3.

Click Done. The newly created inspection will now be the current inspection.

3.4.2 Changing Running Inspections

To change the running inspection:

1. From the Home screen, click the Yellow button in the top center of the screen that displays the currently running
inspection to display all the stored inspections.

2.

Select the inspection to start and click the Start Running button that appears below it.

3.5 Imager Resolution

The iVu Plus TG Gen2 Series Sensor includes an adjustable resolution up to 752×480 pixels.

3.6 iVu Plus Communication Summary of Ethernet and Serial

The iVu Plus communicates with other devices via Ethernet or a UART serial communications port (RS-232). In order to
establish an Ethernet connection to the sensor, the external device must be configured with the correct IP address and TCP
port to communicate. To use the serial communications connection, port settings for baud rate, data bits, parity, and stop
bits must be configured on the iVu Plus to match the settings of the external device.

16 www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

3.6.1 Communication Channels

The iVu Plus TG

supports up to four communications channels. To access the channels, go to Main Menu > System >

Communications.

Command Channel—a bi-directional communication protocol that currently supports ASCII and enables other

•
devices to remotely control the iVu Plus sensor and access sensor results

• Industrial Ethernet—a bi-directional communication channel that allows the user to control the sensor and access
sensor results using Ethernet/IP, Modbus/TCP, or PCCC protocol

• Data Export—used to export selected inspection data to a remote device

• Image Export—used to export inspection images to a remote device

Data export and command channel can be configured for either Ethernet or Serial I/O (but not both); image export is only
available over Ethernet. The table below briefly summarizes valid communication channel configuration options.

Command Channels

Command Channel Yes No No Yes Yes No
Industrial Ethernet Yes No Yes No Yes No
Data Export Yes No Yes No No Yes
Image Export Yes No Yes No Yes No

Scenario #1 Scenario #2 Scenario #3

Ethernet Serial I/O Ethernet Serial I/O Ethernet Serial I/O

3.7 Trigger Modes

The iVu Plus TG has five trigger modes that determine how the sensor captures and processes images:

•

External

• Internal

• Free Run

• Industrial Ethernet Only

• Command

Select one of the trigger modes by accessing Main Menu > Imager > Trigger on the iVu touch screen display. Trigger
on page 33 describes these trigger modes in more detail.

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

3.8 Mask

Use this feature to place mask ROI(s) to exclude portions of an image from the running sensor. It is available on Area and
Blemish sensors.

See Configuring a Mask on page

75 for more information.

18 www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

4 Home Screen

The Home screen
the part being inspected is centered on the screen with the feature of interest bounded by the Region of Interest (ROI), a
rectangle as shown below. The ROI can be rotated and resized, and is highlighted when selected for adjustment.

In the following graphic, there are 2 ROI because it is a multi sensor inspection. The green annotations indicate the object
passes, and the red annotations indicate a failure. This sample inspection failed as shown by the red X next to the Display
mode button.

on the iVu Series sensor display is used to monitor inspections and to configure the sensor. Normally,

4.1 Display Mode

Main Menu > Home

Use the display mode button on the upper left corner of the screen to cycle through all three display modes. The 3 display
modes include: Image with Annotations, Image without Annotations, and Inspection Statistics.

4.1.1 Image with Annotations

Click the display mode icon
pass or fail in the ROI.

> Display Mode (icon)

to show the image with the annotations on. The green or red areas indicate sensors that

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

4.1.2 Image without Annotations

Click the display mode icon to see the image without the annotations from the sensors.

4.1.3 Inspection Statistics

To access the Inspection Statistics, click the Display mode icon
The Inspection Statistic mode has three pages:

•

History

• Inspection Result

• Inspection Inputs

Click the arrows to access the other pages.

.

Inspection Results

The Inspection Result screen shows data about the current inspection being viewed.
The table contains result of each sensor in the inspection. To view details of each sensor, click on the + icon. If a sensor

fails, its box will be drawn in RED. An icon besides the sensor name indicates the reason of its failure.

History

The History screen shows inspection history from sensor reboot, or the last time the statistics were reset, including:

Total Frames—Total number of objects counted

•

• Passed—running total of parts that passed inspection

• Failed—running total of parts that failed inspection

• Missed triggers—running total of missed triggers

• Time Range—minimum and maximum inspection times observed

Click the Reset button to reset statistics.
The table contains history of each sensor in the inspection. Data of each sensor can be expanded or collapsed as required

using the +/–. The green area indicates the sensor passed, red indicates fail. If a sensor fails, an icon besides the sensor
name will indicate the reason of failure.

20 www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

Inspection Inputs

The Inspection Input page has the sensor settings. Use this page to verify what inspection input settings were used on the
latest inspection. Click + to expand the inspection information, or – to collapse the inspection information. Use the right
arrows as a shortcut go to a sensor setting screen.

www.bannerengineering.com - Tel: [phone]

Imager

Strobe

Auto Exposure

Exposure

Gain

Trigger

Focus

External

Internal

FOV

Resolution

* Visible when Motion = Enabled

Add New

Startup

Delete

Stored Inspections

Sensors

Properties

Inspection ID

Motion **

Motion *

Number of Edges

Sensitivity

Rotation

Area

ROI and Mask

Intensity Range

Area Range

Pass Count

Blemish ROI and Mask

Sensitivity

Edge Length Range

Pass Count

Match ROI Type

Percent Match

Rotation Range

Pass Count

Sort

Saved Patterns

Percent Match

Rotation Range

Pass Criteria

Sensor Type selection determines
first menu item under inspection

Inspection Name

Set Name / ID

Locked

Inspection Logs

System Logs

Communication Logs

Unlock Sensor

Logs

Inspection Logs

System Logs

Communication Logs

Command Channel

Data Export

Image Export

Locked Sensor Menus

Industrial Ethernet

Setup

View Logs

Setup

View Logs

Live

Demo

Information

Mode

Save to USB

Load from USB

Reset to Defaults

Configuration

Lock Device

Serial I/O

Data Export

Image Export

Communications

Connection

Data to Export

Output Format

Input Polarity

Input Pullup

Output Type

Output 1

Discrete I/O

Command Channel

Connection

Connection

Delimiters

Fail Hold Time

LCD Timeout

Touch Calibration

Advanced

Display Settings

Output 2

Output 3

Reboot Sensor

Firmware Update

Language

Ethernet I/O

Advanced

Image Type

Advanced

Industrial Ethernet

Connection

Status

View Logs

** Visible when Inspection
contains Area or Blemish

Inspection

Timeout

Map

Select

System

Timeout

iVu Plus TG Gen2 Image Sensor

5 Main Menu Reference

5.1 Main Menu

The Main Menu has four sections:

• Inspection—to modify inspection settings

• Imager—to run the Auto Exposure routine and to make adjustments to functions like exposure, gain, and strobe

• System—to select the sensor Type and to manage the device

• Logs—to configure and view System and Inspection Logs

22 www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

5.1.1 Icon Reference

Action Icons

Icon Description

The Main Menu icon is displayed on the bottom-left corner of the sensor display on the Home screen. It
provides access to sub-menus that are used to set up the sensor.

The Inspection menu icon is located on the the Main Menu, and provides access to parameters that need
to be set for the current and all stored inspections.

The Imager menu icon is on the Main Menu, and lists parameters that affect the characteristics of the
captured image.

The System menu icon is on the Main Menu, and is used to manage the sensor.

The Logs menu icon is on the Main Menu, and is used to set up, view, and save Inspection,
Communications, and System Logs.

The Home Screen icon is displayed in the upper-left corner of the sensor display when viewing menus and
parameter screens in the Main Menu. It is used to quickly return to the Home Screen.

The Display Annotations icon is one of three icons displayed in the upper-left corner of the sensor while
monitoring inspections on the Home Screen. Click this icon to highlight features that the sensor finds.

The Hide Annotations icon is one of three icons displayed in the upper-left corner of the sensor while
monitoring inspections on the Home Screen. Click this icon to disable highlighting.

The Show Statistics icon is one of three icons displayed in the upper-left corner of the sensor while
monitoring inspections. Click this icon to show inspection results and input parameters.

The Hide Log Timestamps icon is one of the icons displayed in the upper-left corner of the Logs screen.
Click this icon to hide the time stamp for the Logs.

The Show Log Timestamps icon is one of the icons displayed in the upper-left corner of the Logs screen.
Click this icon to show the time stamp for the Logs.

The Go Back icon is located on the lower-left of the screen while working in the Main Menu. The Go Back
icon is used to return to the previous screen or menu.

The Help button is located in the upper-right of the screen and provides context-sensitive help for each
screen.

The Manual Trigger icon is located on the lower-right of the sensor display on the Home screen and is
used to manually capture a new image.

The Save icon is used to save data to USB drive, and is available at the bottom of screens such as the
Logs screens.

The Touch Calibration screen displays the Touch Calibration point at various locations on the screen.
Every time the icon displays, the user taps the center of the icon to calibrate the screen.

The Zoom Out icon is located on the right of the screen and is used to reduce magnification of the image
being displayed.

The Zoom In icon is located on the right of the screen and is used to magnify the image being displayed.

The Intensity Selector is located on the left of the of the Intensity Range screen and is used to select the
shade of one of the objects of interest.

The Decrement icon decreases the currently displayed parameter value by one interval. To quickly
decrement the value, press and hold the icon.

The Increment icon increases the currently displayed parameter value by one interval. To quickly
increment the value, press and hold the icon. In the Sort tool, this icon is used to indicate one of the ten
storage locations for patterns.

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

Icon Description

The Add Mask icon displays on the left side of the screen when masking is enabled. Press to add a mask
to the currently selected sensor.

The Delete Mask icon displays on the left side of the screen when a mask is selected. Press to delete a
mask from the currently selected sensor.

The Circular Mask icon displays on the left side of the screen when a mask is selected. Press to cycle
through and select a Circular, Elliptical, or Rectangular-shaped mask.

The Elliptical Mask icon displays on the left side of the screen when a mask is selected. Press to cycle
through and select a Circular, Elliptical, or Rectangular-shaped mask.

The Rectangular Mask icon displays on the left side of the screen when a mask is selected. Press to cycle
through and select a Circular, Elliptical, or Rectangular-shaped mask.

Display Icons

Icon Description

The Inspection Passed icon is located in the upper-left of the screen, and indicates that the last inspection
passed its test conditions.

One of the possible Inspection Failed icons located in the upper-left of the screen, it indicates that the last
inspection failed.

One of the possible Sensor Failed icons located in the Inspection Statistic table, it indicates that the
sensor failed because the number of objects exceeded the test count.

One of the possible Sensor Failed icons located in the Inspection Statistic table, it indicates that the
sensor failed because there were fewer objects than specified by the test count.

One of the possible Sensor Failed icons located in the Inspection Statistic table, it indicates that the
sensor failed because the inspection timed out.

One of the possible Inspection Failed icons located in the upper-left of the screen, it indicates that the
sensor is in fail hold mode.

The Sensor Locked icon is located in the upper-left of the screen, and indicates that the sensor is in a
locked state. If no icon is displayed, the sensor is unlocked.

Communications Log Icons

Icon Description

Port opened.
Port closed.
Indicates that the command has been processed without errors.

Indicates that the incoming entry is stalled (no new bytes), or end-of-frame delimiter was not received, or
client is not reading data on ethernet

If the response frame contains an error or is dropped, the log entry icons for the request and the
response frames will be colored red, and the displayed error count will increment by one.

If the command takes a long time to process, the last long entry will change to an hourglass (for
example, during trigger of long inspections).

.

5.2 Inspection Menu

Main Menu > Inspection

The Inspection menu
sensor has specific settings that are available. It is also where stored inspections can be managed.

24 www.bannerengineering.com - Tel: [phone]

icon is located on the Main Menu and is where settings for inspection can be adjusted. Each type of

iVu Plus TG Gen2 Image Sensor

5.2.1 Sensors Menu

Main Menu

This menu shows the list of sensor(s) that are included in the current inspection. Use the Add Sensor button add a new
sensor into the current inspection.

> Inspection > Sensors

Area Menu

Main Menu > Inspection > Sensors > Area

When configured as an Area sensor, the sensor is used to ensure that one or more features of interest are present on a
part. To configure as an Area sensor, set four parameters:

• ROI and Mask (Rectangle, Elliptical, or Circle) and enabling the mask function

• Intensity Range (range of gray scale values) of a feature of interest

• Area Range, or size range of a feature of interest

• Pass Count

To see a working example of the sensor configured as an Area sensor, see Demo Mode.

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

ROI and Mask

Main Menu > Inspection > Sensors
The Region of Interest (ROI) is the user-defined area on the screen that the sensor will analyze. The ROI type can be

rectangular, elliptical, or circular. From the menu , select the ROI type to use for the inspection. Adjust the ROI as
appropriate for your inspection. An ROI can be as large as the entire Field of View (FOV).

Select the Enable Mask checkbox to allow mask ROIs to be used with the inspection ROI.

> Area > ROI and Mask

Intensity Range

Main Menu > Inspection > Sensors > Area > Intensity Range
Intensity Range is the range of gray scale values the sensor should look for. To set the Intensity Range, use the eye

dropper on the left of the screen to select the target feature, then use the slider bar at the bottom of the display to fine
tune the selection. As the slider bar is moved, green highlighted areas indicate objects the sensor finds.

NOTE: Objects that are colored yellow are found, but filtered out. This is because the objects fall
outside of the Area Range. See Area Range to adjust this setting.

Area Range

Main Menu
The Area Range is used to set the size limits of a feature of interest. Use the slider bar at the bottom of the display to

select the range. Areas are measured by counting pixels. For example, a rectangular feature that is 100 pixels wide by 200
pixels tall will have an area of roughly 20,000 pixels.

> Inspection > Sensors > Area > Area Range

Pass Count

Main Menu > Inspection > Sensors > Area > Pass Count
The Minimum Pass Count is the minimum number of parts, labels, or features expected to fall within the specified criteria;

the Maximum Pass Count is the maximum number expected to fall within the specified criteria. These settings are used to
determine the pass or fail result of the inspection.

Blemish Menu

Main Menu > Inspection > Sensor > Blemish

When configured as a Blemish sensor, it can be used to find flaws on a part (for example, scratches on a disc). It can be
used to make sure the a feature exists on a part. Although this is more commonly an application for a sensor configured as
an Area sensor, a Blemish sensor may be a better option to find a feature when dealing with variable materials or uneven
lighting. Some sample applications include:

• Inspections that check for scratches on a part, and reject parts where the scratches are too numerous or larger
than acceptable

• Inspections that check for the presence of some label or marking on a part that may vary in color

To configure as a Blemish sensor, select the ROI type, and set the Sensitivity, Size Filter, and Pass Count.

26 www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

ROI and Mask

Main Menu > Inspection > Sensors
The Region of Interest (ROI) is the user-defined area on the screen that the sensor will analyze. The ROI type can be

rectangular, elliptical, or circular. From the menu, select the ROI type to use for the inspection. Adjust the ROI as
appropriate for your inspection. An ROI can be as large as the entire Field of View (FOV).

Select the Enable Mask checkbox to allow mask ROIs to be used with the inspection ROI.

> Blemish > ROI and Mask

Sensitivity

Main Menu > Inspection > Sensors > Blemish > Sensitivity
Sensitivity is used to fine-tune how sensitive the sensor is to finding blemish or other edges within the ROI. The Sensitivity

value helps account for light variations that might affect how well the sensor detects edges on inspected parts. The
Sensitivity scale is from 0 to 100 where 0 means least sensitive and 100 means most sensitive. If set near 0, the sensor
will only find very sharp edges with strong contrast. If set near 100, the sensor will find very dim or blurry edges, and may
be unstable.

Edge Length Range

Main Menu > Inspection > Sensors > Blemish > Edge Length Range
The sensor counts all the edge pixels it detects in the ROI. The bar at the bottom of the Edge Length Range screen shows

all the different contiguous edge segments found. Edge segments within the two brackets [ ] are highlighted in green and
those outside the brackets are ignored and colored yellow. Use the slider bar to specify the edge length range in pixels.
Edges found within this range will be considered to calculate the Pass Count.

Pass Count (Pixels)

Main Menu > Inspection > Sensors > Blemish > Pass Count
The Minimum Pass Count is the minimum number of pixels expected to fall within the specified criteria; the Maximum Pass

Count is the maximum number of pixels expected to fall within the specified criteria. These settings are used to determine
the pass or fail result of the inspection.

Match Menu

Main Menu > Inspection > Sensors > Match

When the sensor is configured as a Match sensor, set the ROI Type, Percent Match, Rotation Range, Pass Count, and
Timeout for the inspection. To see a working example of the sensor configured as a Match sensor, see Demo Mode.

ROI Type

Main Menu > Inspection > Sensors

> Match > ROI Type

The Region of Interest (ROI) is the user-defined area on the screen that the sensor will analyze. The ROI Type can be
rectangular, elliptical, or circular. From the menu at the bottom of the ROI Type screen, select the ROI Type to use for the
inspection. Adjust the ROI as appropriate for your inspection. An ROI can be as large as the entire Field of View (FOV).

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

Percent Match

Main Menu > Inspection > Sensors
The Percent Match setting adjusts for how closely the inspected part or label matches the reference part or label. The

Percent Match scale is from 0 to 100 where 0 is the most tolerant and 100 is the least tolerant. Move the slider to the left
or to the right.

> Match > Percent Match

Rotation Range

Main Menu > Inspection > Sensors > Match > Rotation Range
The Rotation Range sets the expected rotation of parts or labels during an inspection. For example, a value of 45 means

that the part may rotate 45 degrees in either direction from the reference part and still pass. Move the slider from 0 to 180
degrees.

NOTE: The smaller the rotation range, the faster the inspection will run.

Pass Count

Main Menu > Inspection > Sensors
The Minimum Pass Count is the minimum number of parts, labels, or features expected to fall within the specified criteria;

the Maximum Pass Count is the maximum number expected to fall within the specified criteria. These settings are used to
determine the pass or fail result of the inspection.

> Match > Pass Count

Timeout

Main Menu > Inspection >Sensors > Match > Timeout

When the sensor type is set as Match or Sort, this screen provides for adjusting the maximum time the inspection is
allowed to execute. A timeout error is reported in the case inspection runs out of time. If this value is set too high, the
sensor can miss triggers while trying to detect a bad pattern.

Sort Menu

The Sort sensor is used to identify and sort up to 10 stored patterns. The menu items in the Sort sensor provide for
managing stored patterns and configuring Sort sensor inspection parameters.

The Sort sensor cannot be added if any other sensors are selected. The Sort menu can only be reached when adding a
sensor.

Saved Patterns

Main Menu > Inspection > Sensors > Sort > Saved Patterns

When configuring a Sort
to save a taught pattern to an empty pattern storage location or to overwrite an existing pattern. This screen is also where
patterns can be deleted from a storage location, named, or renamed.

sensor type, there are 10 pattern storage locations available. The Saved Patterns screen is used

Percent Match

Main Menu > Inspection > Sensors > Sort > Percent Match

28 www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

The Percent Match setting adjusts for how closely the inspected part or label matches the reference part or label. The
Percent Match scale is from 0 to 100 where 0 is the most tolerant and 100 is the least tolerant. Move the slider to the left
or to the right.

Rotation Range

Main Menu > Inspection > Sensors > Sort > Rotation Range

The Rotation Range
that the part may rotate 45 degrees in either direction from the reference part and still pass. Move the slider from 0 to 180
degrees.

sets the expected rotation of parts or labels during an inspection. For example, a value of 45 means

NOTE: The smaller the rotation range, the faster the inspection will run.

Pass Criteria

Main Menu > Inspection >Sensors > Sort > Pass Criteria

There are four options to select from to define pass criteria for a Sort sensor inspection, which are described below using
an example where there are two saved patterns.

Any Saved Pattern—Pass condition if the sensor matches either Pattern_1, Pattern_2, or both

•

• All Saved Patterns—Pass condition if the sensor matches both Pattern_1 AND Pattern_2

• Single Saved Pattern—Pass condition if the sensor matches either Pattern_1 OR Pattern_2, but NOT both

• Specific Saved Pattern (requires selecting a saved pattern to match; for example, Pattern_2) - Pass condition when
the sensor matches only Pattern_2

Timeout

Main Menu > Inspection > Sensors > Sort > Timeout

When the sensor type is set as Match or Sort, this screen provides for adjusting the maximum time the inspection is
allowed to execute. A timeout error is reported in the case inspection runs out of time. If this value is set too high, the
sensor can miss triggers while trying to detect a bad pattern.

5.2.2 Motion Menu

Main Menu > Inspection > Motion

Enable Motion when the part is expected to move or rotate. Motion settings also involve selecting the number of edges to
locate, adjusting sensitivity, and selecting whether or not rotation is enabled. These settings appear on the Inspection
Menu after Motion is set to 'Enabled'. Motion is enabled when Area and/or Blemish sensor are included in the inspection.

Number of Edges

Main Menu > Inspection > Motion > Number of Edges

On the Number of Edges
tracked in one direction (by default, horizontally); if Two Edges is selected, motion can be tracked horizontally and
vertically.

screen, use the radio buttons to select One Edge or Two Edges. If One Edge is selected, motion is

www.bannerengineering.com - Tel: [phone]

iVu Plus TG Gen2 Image Sensor

Sensitivity

Main Menu

Sensitivity is used to fine-tune how sensitive the sensor is to finding a reference edge. The Sensitivity value helps account
for light variations that might affect how well the sensor detects edges on inspected parts. The Sensitivity scale is from 0
to 100 where 0 means least sensitive and 100 means most sensitive. If set near 0, the sensor will only find very sharp
edges with strong contrast. If set near 100, the sensor will find very dim or blurry edges, and may be unstable due to
noise within the image.

> Inspection > Motion > Sensitivity

Rotation

Main Menu > Inspection > Motion > Rotation

Rotation can be Enabled or Disabled. Select Enabled if the part can be expected to rotate during the inspection.

5.2.3 Properties Menu

Main Menu > Inspection > Properties

The Properties menu is used to select a Sensor Type and specify an Inspection Name. Additionally, if the Sensor Type is
Match or Sort, an option to define a timeout for the inspection.

Inspection Name

Main Menu > Inspection > Properties > Inspection Name

The Inspection Name

screen displays the name of the current inspection. You can edit the name of the inspection here.

Inspection ID

Main Menu > Inspection > Properties > Inspection ID

Click on the dropdown arrow to view a list of IDs assigned to all inspections on this device. Choose any unused ID to
change the ID of this inspection. The original ID will be marked as 'Unused'.

You may also swap the ID of this inspection with another inspection by selecting that inspection on the list.

5.2.4 Stored Inspections

Main Menu > Inspection > Stored Inspections

Stored Inspections is used to manage stored inspections. Management of stored inspections includes adding, deleting, and
specifying which inspection should be defined as the Startup inspection.

30 www.bannerengineering.com - Tel: [phone]