Banner PresencePLUS PPM8 LCD Color Monitor User Manual

Vision Sensors & Lighting
THIRD EDITION
®
New models to solve your toughest inspection challenges.
PresencePLUS® Pro & P4 COLOR
Ruggedized Pro Cameras & Lights
P4 OMNI
Offers color sensing in two convenient packages.
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Bar Code Reading
Lighting
A compact, integrated vision sensor with features for the most demanding applications.
Page 16
Decodes 2D and 1D linear bar codes in the toughest low­light/low-contrast conditions.
Page 10
Offers a complete selection of basic and specialty lighting solutions to enhance vision capabilities.
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Contents

When the world thinks of sensors, it thinks of Banner.
With more than 17,000 photoelectric, ultrasonic and vision sensors, and safety products available worldwide, Banner is the most innovative, most experienced name in sensors. For simple to complex applications, Banner has more sensor solutions than any other manufacturer.
The innovation leader with more than 40 years of sensor development and application expertise, Banner understands the challenges of sensing in manufacturing and process industries. Banner has more than 3,000 factory and eld representatives worldwide, as well as the largest force of application engineers in the industry who solve thousands of the most challenging applications every year.
PresensePLUS Vision Sensing 4
Machine Vision Solutions 6
Color Analysis Solutions 8
ID, Bar Code and Traceability Solutions 10
PresensePLUS Software & Inspection 12
PresensePLUS Features Comparision 14
PresensePLUS Pro and P4 OMNI 16
P4 Dedicated-Function Sensors 18
Pro Sensors & Kits 20
P4 Sensors & Kits 22
Specications 24
Hookups & Dimensions 26
System Selection & Integration 28
Lighting Selection Guide 30
Lenses 39
Brackets 40
Monitors & Indicators 43
Cables & Cordsets 44
Interface Modules 46
Power Supplies 46
3
OPPOSED
RETROREFLECTIVE
Advanced vision solutions from the number one name in sensors.
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Vision sensing from the source you trust.
As the prefered brand of sensors worldwide, Banner knows the challenges of the factory oor. That’s why we designed our line of PresencePLUS® vision sensors from the ground up, with advanced features, easier setup and operation, rugged design, the most value of any vision systems in the market and, most of all, Banner reliability and support.
A complete solution.
From a single inspection point to plant-wide vision integration, Banner oers complete vision solutions. Vision sensing has two major elements: hardware—the camera, controller, lighting and brackets; and software— the control system, graphical user interface and image algorithms. Banner provides all of the elements to successfully deploy vision sensing in your facility.
Visual Inspection Process
1. Acquire an image of the part.
2. Analyze the image. Determine if the inspection passes or fails, and report the
3. results to the manufacturing line. The part then either passes to the next process or is rejected and removed.
1. Sensor: The sensor contains the imager, microprocessor and I/O. The imager has an array of tiny light-sensitive cells (pixels) that convert the target into an image. The microprocessor analyzes the image and makes determinations about it based on user-determined tolerances and criteria. The sensor exports the inspection results through some type of I/O, such as discrete, Ethernet or serial.
The lens focuses the light onto the sensor’s
2. Lens:
imager. To determine the lens focal length for an applications, specify the field of view and working distance.
3. Light Source:
The light source is a critical component of any vision inspection system. Lighting is the most powerful tool for creating contrast to amplify the feature of interest, while minimizing other features of the part. Selecting the best light source depends on the shape, surface texture, color and opacity of the part.
Opposed Mode
Proximity Mode
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Part Light Source Lens Imager Sensor
Process the image,
make a decision
ACQUIRE ANALYZE DETERMINE
Output Results
Backlight Ring Dome Directional Low-angle On-axis
Aordable sensing technology that’s easy to use.
The best value in vision.
• The best price-performance ratio brings full vision capabilities to all sensor speciers.
• Simple, easy-to-use interface.
• Easy to justify cost for multiple applications.
• No software maintenance fees—free rmware & PC software upgrades.
• Hundreds of lens and lighting options.
• Superior in-house manufacturing and quality.
The easiest-to-use vision sensors available.
• Easy, menu-driven, point and click interface.
• Remote TEACH input similar to a photoelectric sensor.
• Simple inspection changeovers.
• Live video display without a PC.
• User interface software that allows setup and seamless operation in nine languages.
“ The substantially lower cost of
the Banner vision sensor makes it feasible to set up more inspection systems.”
–Major automotive manufacturer
“ One of the most benecial, yet
simple, advantages of the Banner vision sensor was its TEACH tool. This tool was extremely valuable for eliminating guess work and applying the statistical variation.”
–Automotive engineer
The best vision sensor performance.
• Inspection speeds faster than 10,000 parts per minute.
• Full 360° xture-free inspection.
• Locates inspection detail, regardless of orientation.
• Solves the most applications in your plant.
• Full suite of grayscale, color and binary vision tools.
More sensors, more solutions, more customer support.
• Superior vision products from the leader in sensing.
• More than 17,000 photoelectric, ultrasonic and vision sensors available worldwide.
• Experienced factory application engineers to solve your most advanced sensing challenges.
• More than 3,000 trained factory and eld representatives worldwide.
• Complete factory training, eld training and online training.
• Helps you achieve 100% quality inspection and zero defect manufacturing.
“ The PresencePLUS® vision sensor
not only saved time and freed up our quarantined product, it pro­vided a level of documentation.”
–Metal stampings manufacturer
“ I appreciate the level of expertise
the eld rep showed with the PresencePLUS sensors and how he has helped me with other dicult applications in the past.”
–Major consumer goods
manufacturer
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Machine vision made simple.
Robust inspection solutions. With more advanced capabilities.
From simple verication to complex inspection, Banner has the most powerful and aordable vision systems and sensors, built to perform in high-speed manufacturing and production environments. Banner provides an alternative to costly, complex machine vision systems with proven, easy-to-use and aordable self-contained vision sensors for real-world applications.
Select the PresencePLUS® Pro which incorporates remote cameras paired with powerful controller units featuring 11 location, vision and analysis tools. Or, choose the versatile new, self-contained PresencePLUS
Banner Machine Vision
P4 OMNI with easy TEACH setup. To deploy the precise inspection capability where you need it, select from four PresencePLUS P4 series vision sensors with dedicated functionality.
Banner machine vision solutions are available in standard resolution and high-resolution 1.3 megapixel models for more detailed inspections, as well as sealed, IP68-rated models for rugged industrial and washdown environments. P4 models are available in both in-line and right-angle congurations. These options, as well as a complete selection of Banner lenses, lighting and brackets, provide complete, high-speed inspection capabilities in the vast majority of applications.
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EXAMPLE APPLICATIONS
Add inspection capabilities where you need them. PresencePLUS® Pro and P4
vision sensors integrate easily into existing production systems to provide new levels of quality control, error proong and verication.
Vial Fill Level and Cap Seal Verication
To rapidly verify that vials are lled to the correct level and that caps are correctly aligned, a high-speed PresencePLUS P4 EDGE vision sensor locates the vial and veries the ll level and cap placement.
Food Packaging Error Proong
Each unit of pastry dough is inspected by a PresencePLUS P4 AREA vision sensor to detect the presence of a frosting
packet—ensuring that one is included in each package.
Rivet Inspection
Following installation of a rivet into each corner of an automobile steering wheel horn frame assembly, the component passes beneath a PresencePLUS Pro vision sensor to verify the presence and quality of each rivet.
A high-resolution PresencePLUS P4 EDGE 1.3 vision sensor combines with a laser line to inspect the beveled gum wedge of continuously extruded rubber. The laser line bends at the bevel, allowing a cost-eective two­dimensional vision sensor to perform a three-dimensional measurement.
Stamped Metal Pin Inspection
To verify the quantity, pitch and straightness of connector
pins on a stamped metal subassembly, the high-resolution PresencePLUS P4 OMNI 1.3 vision sensor counts the number of connector pins, simultaneously detecting irregular gaps that indicate pins are bent or missing.
Color Vision Sophistication. Banner Simplicity. Banner’s PresencePLUS® Pro COLOR
and P4 COLOR vision sensors combine with the comprehensive suite of PresencePLUS inspection tools to deliver an easy-to-apply, color-based vision inspection solution of extraordinary sophistication for signicantly less than comparable systems.
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Color Solutions
Unlimited color spectrum analysis for your most challenging applications.
For inspection features best examined by spectral analysis, Banner offers solutions designed to meet your requirements and fit your machinery. The new one­piece PresencePLUS® P4 COLOR OMNI and the compact PresencePLUS® Pro COLOR sensor with a separate DIN-mountable controller offer two powerful platforms for color vision applications—with all of the robust inspection tools and capabilities of their gray scale counterparts.
PresencePLUS Pro COLOR and P4 COLOR OMNI vision sensors inspect unlimited color variations visible in the camera’s field of view. Shape and color data can be combined to identify minute variations and color consistency can be monitored within a taught range of acceptable color.
Combining intuitive PresencePLUS software, remote TEACH for rapid configuration and a precision 752 x 480 pixel resolution color CMOS imager, PresencePLUS Pro COLOR and P4 COLOR OMNI vision sensors inspect for a specific color or color range taught to the sensor with the Color Match tool. All models include the powerful suite of gray scale vision tools—including Locate, Pattern Find and Count, Geometric Find and Count, Edge, Object, Blob and Average Gray Scale—that deliver extraordinary precision and versatility, for the most demanding inspections.
EXAMPLE APPLICATIONS
Candy Color Inspection
A PresencePLUS P4 COLOR OMNI mounted above a conveyor inspects each box of 12 chocolates, making sure each paper nest contains the correct type, based on color. It rejects boxes that have the wrong chocolate in a nest, are missing product or have damaged product.
Color Inspection and Vericatio
A PresencePLUS Pro COLOR vision sensor veries that pour spouts inserted into detergent bottles are present, fully inserted and of the correct color to match the bottle. The IP68 sealed housing protects the sensor and light from liquids.
Automotive Fuse Box Error Proong
To verify that fuses of the specied amperage are placed in the correct location in an automotive fuse box assembly, a PresencePLUS Pro COLOR vision sensor using a Banner White Area Light provides fast and easy error proong.
Comprehensive Blister Pack Inspection
Tightened federal regulations require critical quality controls in pharma­ceutical packaging. A PresencePLUS Pro COLOR vision sensor under a Banner Tubular Fluorescent Light inspects blister packs to ensure each blister contains the correct tablet, veries each tablet is unbroken, and detects empty blisters or those containing foreign matter.
Cap and Fill Inspectio
As glass bottles pass on a high-speed conveyor, a PresencePLUS P4 COLOR OMNI conrms each bottle is completely lled, while verifying the stopper is fully inserted and is the correct color. Dual Banner Area Lights bracket directly to the sensor to create the optimum contrast for the inspection.
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ID, Bar Code and Traceability Solutions

EXAMPLE APPLICATIONS
Accurately reads and grades 2D and 1D bar codes.
A traceability program is only as successful as the vision sensor that reads 2D or 1D bar codes under plant conditions. That’s why major manufacturers depend on the industry’s most reliable sensor expert for their vision needs. Banner’s PresencePLUS® Pro and P4 OMNI with optional bar code reading software offer tremendous power and flexibility, for accurate high-speed bar code reading in the toughest environments. The PresencePLUS® P4 BCR and high-resolution BCR 1.3 vision sensors have been developed from the ground up for the most robust 2D and 1D linear bar code reading capabilities—even when conditions and codes are less than ideal.
Whether for production traceability of direct-marked manufactured components or to verify product lots for consumer goods, Banner PresencePLUS sensors are engineered to oer the highest read rates in low contrast/poor visibility conditions, or where marked or formed bar codes have degraded. The BCR is “taught” the correct codes, either with the sensor itself or over an industrial Ethernet network (EIP or Modbus TCP/IP). Banner’s dedicated BCR solutions keep lines moving by reading despite problems such as low contrast, shadows, orientation, surface variations or marking variables resulting from degraded etching, stamping or printing.
BCR models read 2D Data Matrix ECC200 and 1D linear bar codes such as Code 39, Code 128, Codabar, Interleaved 2 of 5, EAN-8 and EAN-13 (supports UPC-A), UPC-E and Postnet. High-resolution BCR 1.3 models (1280 x 1024 pixels) feature 1.3 megapixel imaging that reads and grades smaller bar codes, or allows larger fields of view. Codes and code grades can be communicated using the BCR’s serial port.
2D Stamped Bar Code Verication
Manufacturing lots can be tracked for quality assurance using a PresencePLUS Pro bar code reader to detect and verify a subtle 2D bar code stamped into metal parts. Advanced 2D capabilities and a Banner Low-Angle Ring Light facilitate detection of bar codes subject to stamping quality variables.
Simultaneous Verication of Two Bar Code
The high-resolution PresencePLUS P4 BCR 1.3 delivers an extended eld of view to read 1D linear and 2D bar codes simultaneously to verify components in an assembly are correctly paired. Strobed ring lighting and 1.3 megapixel resolution provide increased image repeat rates for accurate reading at full line speed.
Large Area Verication for Sorting and Die Protection
The dies in tire presses suer costly damage if the press tries to stamp tread into an unstamped, or green, tire of the wrong size. To direct each tire to the correct press at production line speeds, a series of six high-resolution PresencePLUS P4 BCR 1.3 vision sensors sort green tires based on bar code data printed on a label on the tire’s bead, regardless of position or orientation.
Miniature Bar Code Vericatio
The advanced functionality of the PresencePLUS P4 BCR reads and veries miniaturized symbology, such as 2D bar codes, on small electronic components. A Banner Backlight through the semi-transparent circuit membrane optimizes contrast of the code for optimal reading conditions at high line speeds.
Pharmaceutical Product ID and Lot Contro
Federal pharmaceutical product identication and lot control requirements are both stringent and evolving. The PresencePLUS Pro gives you the power and exibility to future-proof inspection, verication and tracking capabilities.
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Part traceability using direct-marked 2D Data Matrix bar codes
demands extraordinary levels of reliable performance from code reading tools. With a proven foundation of industrial sensor reliability, Banner’s PresencePLUS® P4 BCR sensors handle the toughest 2D and 1D bar code reading chores at the highest throughput rates.
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Setting up an application is easy. Advanced PresencePLUS® software
oers point-and-click setup without any knowledge of programming languages. Set up an inspection by simply illuminating the target, focusing the camera and selecting the features to analyze.
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Software and Tools
9
Languages
Powerful Inspection Tools. One Advanced Software Platform.
Fullling the capabilities of powerful PresencePLUS® vision sensor hardware requires an equally advanced software solution. One that operates seamlessly across all Banner vision products. One that provides a common, intuitive graphical interface. One so advanced, it can literally teach itself your vision challenge.
Banner’s versatile PresencePLUS software does just that. Now conguring sophisticated vision applications is faster and easier than ever before, while common applications are virtually plug-and-play.
Features:
• Seamless functionality across the entire Pro and P4 vision sensor series.
• Remote TEACH input similar to a photoelectric sensor self-learns the inspection tolerances of your application.
• Easy, menu-driven, point-and-click interface on a PC.
• Simple push-button inspection changeovers.
• Live video display without a PC.
• ActiveX utilities for exporting inspections, images and results.
• Direct connectivity to EtherNet/IP and Modbus TCP industrial networks.
• In nine languages including English, Simplied Chinese, Traditional Chinese, French, German, Japanese, Portuguese and Spanish with translated text, buttons, commands and icons in the respective language.
• Operates on Microsoft Windows® operating systems.
• Free web download or CD-ROM; includes all Banner vision sensor manuals, troubleshooting guides, and lens and lighting selection guides.
• Free rmware and software upgrades.
PresencePLUS Software Operation
3-point click-and-go Intuitive, wizard-like graphics walk the oper­ator through adjusting the sensor position, selecting the features to inspect, operating the sensor and monitoring its outputs.
Setup Dynamically view the sensor image, adjust the lighting position and intensity, and then focus the lens to maximize contrast between target features and the background.
PresencePLUS: A Comprehensive Suite of Inspection and Analysis Tools.
LOCATION TOOLS compensate for translational and
rotational movement.
Locate Determines translation and rotation by detecting relative movement of edges
Pattern Find Determines translation and rotation by detecting relative movement of a pattern
GEO Find Determines translation and rotation movement of a part up to 360° by detecting relative movement of a pattern
VISION TOOLS
Color Match Inspects for matching hue
and intensity
Average Gray Scale Determines the gray scale intensity value of an area
Blob Determines the presence, connectivity, size and location of selected features
Edge Determines the presence, number, classification and location of edges
Object Determines the presence, number, classification, size and location of objects
Pattern Count Determines the presence, number and location of pattern(s)
GEO Count Detects the presence and location of a target pattern in any orientation
Bar Code Finds, decodes and grades advanced 2D and 1D linear bar codes
ANALYSIS TOOLS
of the vision tools.
Measure Measures distance and angles between two prescribed points or lines
Math Performs arithmetic functions on any tool or constant
analyze the image.
measure and evaluate the results
COMMON
Tools Highlight the features to inspect while selecting tools and lters to maximize robust operation. Choose criteria and margins for good or failed outputs. Select data or images to communicate through the Ethernet or serial ports.
Run Operate inspections and sensor outputs while viewing images or exploring the detailed, comprehensive inspection results. Select the inspection to run. Log any inspection to archive its images and results.
User Interface
across all Banner Vision products
Test Evaluates results of selected vision and analysis tools to determine whether an inspection passes or fails; performs logical operations; and activates outputs
Communication Sends image or results of selected location, vision and analysis tools over the Ethernet or RS-232 serial communication ports to industrial Ethernet or PC networks
FREE Software & Firmware
UPGRADES
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PresencePLUS® Pro & P4 General-Purpose Sensors PresencePLUS® P4 Dedicated-Function Sensors
9
Languages
PROII PROII 1.3 IP68 PROII IP68 PROII 1.3 OMNI OMNI 1.3 AREA AREA 1.3 EDGE EDGE 1.3 GEO GEO 1.3 BCR BCR 1.3
Hardware
Integrated I/O 14 14 14 14 7 7 7 7 7 7 7 7 7 7
Interchangeable Lenses C-mount C-mount C-mount C-mount C-mount C-mount C-mount C-mount C-mount C-mount C-mount C-mount C-mount C-mount
Interchangeable Lighting
Imager CCD CMOS CCD CMOS CCD CMOS CMOS CMOS CMOS CMOS CMOS CMOS CCD CMOS
Resolution 640 x 480 1280 x 1024 640 x 480 1280 x 1024 640 x 480 1280 x 1024 128 x 100 1280 x 1024 128 x 100 1280 x 1024 128 x 100 1280 x 1024 640 x 480 1280 x 1024
Imager Speed 48 fps 18 fps 48 fps 18 fps 48 fps 27 fps 500 fps 27 fps 500 fps 27 fps 500 fps 27 fps 48 fps 27 fps
Color Models
Live Video Output
Power Requirements 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc
Trigger
Memory 64 MB 64 MB 64 MB 64 MB 32 MB 32 MB 8 MB 32 MB 8 MB 32 MB 8 MB 32 MB 8 MB 32 MB
Inspection Storage (Max.) 999 999 999 999 999 999 500 999 500 999 500 999 400 999
Communications
Ethernet 10/100 10/100 10/100 10/100 10/100 10/100 10/100 10/100 10/100 10/100 10/100 10/100 10/100 10/100
Serial RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232
Internal or
External
Internal or
External
Page 20 Page 22 Page 23
Internal or
External
Internal or
External
Internal or
External
Internal or
External
Programmable Discrete I/O 6 6 6 6 4 4 4 4 4 4 4 4 4 4
Programming/Interface
User Interface
Languages Supported
(English, German, Japanese, Chinese,
Spanish, French, Italian, Portugese)
Industrial Ethernet
Protocols
Software Upgrades Free Free Free Free Free Free Free Free Free Free Free Free Free Free
Runs without a PC Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
ActiveX Interface
Quick TEACH
Remote Teach
External Inspection
Storage & Operations
9 9 9 9 9 9 9 9 9 9 9 9 9 9
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
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COMMON
User Interface
across all Banner Vision products
Internal or
External
Internal or
External
Internal or
External
Internal or
External
Internal or
External
Internal or
External
Internal or
External
Internal or
External
EthnerNet/IP & Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
EthnerNet/IP &
Modbus TCP/IP
FREE Software & Firmware UPGRADES
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