Banner R55E User Manual

R55 Expert™ Color Mark Sensors

Parallel to sensor length

Perpendicular to sensor length

Perpendicular to sensor length

CONVERGENT

Color Registration Mark Sensor with Solid-State Light Source

Features

• Outstanding color contrast sensitivity; detects 16 levels of gray scale.

• Reliable detection of the toughest color mark contrasts, including 20% yellow
against white

• Three sensing beam colors: blue, green and white, depending on model

• Fast, 50-microsecond response

• Easy-to-set automatic

Expert-style configuration options: Static and Dynamic TEACH

and Window SET, plus Manual Adjust for fine tuning via push button or remote input

• Non-volatile memory

• Ten-element light bar for clear display of received signal strength

• Fixed-convergent sensing at 10 ±3 mm (0.39" ±0.12")

• Rectangular 1.2 mm x 3.8 mm (0.05" x 0.15") sensing image at 10 mm from the lens

• Horizontal or vertical sensing image, depending on model (see table below)

• Rugged zinc alloy die-cast housing with high-quality acrylic lens suitable for food
processing applications; rated IP67, NEMA 6

• Bipolar (NPN/PNP) discrete outputs with three delay settings (0, 20 or 40 ms)

• 0 to 10 mA analog output; value provides an indication of signal strength.

• Integral cable or QD connector, depending on model

Models Beam Color Cable* Focus

R55ECG1

R55ECG1Q 6-pin Euro-Style QD

R55ECB1

R55ECB1Q 6-pin Euro-Style QD

R55ECW1

R55ECW1Q 6-pin Euro-Style QD

R55ECG2

R55ECG2Q 6-pin Euro-Style QD

R55ECB2

R55ECB2Q 6-pin Euro-Style QD

R55ECW2

R55ECW2Q 6-pin Euro-Style QD

* 9 m (30') cables are available by adding suffix “W/30” to the model number of the cabled version (e.g., R55ECG1 W/30). A model with a QD

connector requires an accessory mating cable. See page 12.

Printed in USA 12/06 P/N 59574 rev. B

Green

525 nm

Blue

475 nm

White

450-650 nm

Green

525 nm

Blue

475 nm

White

450-650 nm

6-wire 2 m (6.5')

6-wire 2 m (6.5')

6-wire 2 m (6.5')

6-wire 2 m (6.5')

6-wire 2 m (6.5')

6-wire 2 m (6.5')

Models

10 mm
(0.39")

Supply

Voltage

10-30V dc

Output

Type

Bipolar

NPN/PNP

and

Analog

0-10 mA

Sensing Image Orientation

R55 Expert™ Color Mark Sensors

SETUP

DO

LO

OFF

Delay

Switch Point

+

DYNAMIC

–

STATIC

Dynamic (+)

Push Button

Switch Point

10-Segment

Bargraph Display

Static (–)

Push Button

DO
(Dark Operate) LED*

* Either LO or DO LED is ON

Whenever sensor has power
and is in RUN Mode

LO
(Light Operate) LED*

Delay Configuration
Indicator LED

Output Conducting
LED

Overview

R55 Expert (R55E) offers maintenance-free, solid-state reliability for all color contrasts found
in common product and material registration applications. Fast 50-microsecond sensing
response produces excellent registration repeatability, even in ultra-high-speed applications.
This fast response, coupled with the small 1.2 x 3.8 mm (0.05" x 0.15") sensing image, allows
color marks to be made small and inconspicuous, while being reliably sensed.

The construction of the R55E is extremely robust, with a die-cast metal housing, plastic
optics, and IP67 and NEMA 6 leakproof design for harsh sensing environments. The sensor's
10-segment bargraph display and the individual indicator LEDs provide easy configuration
and status monitoring.

Indicators

The LED indicators (see Figure 1) operate as follows in RUN mode (normal operation):

Output Conducting LED: ON when outputs are active

Delay Configuration Indicator LED: OFF No OFF-delay is programmed

ON 20- or 40-ms OFF-delay is programmed

Light Operate LED: ON to indicate Light Operate configuration

Dark Operate LED: ON to indicate Dark Operate configuration

(NOTE: Since either one of these is always ON when the sensor is operating, the

combined Light/Dark Operate LEDs also provide a functional Power-ON indication.)

10-Segment Bargraph Display: indicates signal strength, with respect to the sensing
threshold (“switchpoint”).

Figure 1. R55E Series sensor features

2 P/N 59574 rev. B

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

www.bannerengineering.com • Tel: [phone]

R55 Expert™ Color Mark Sensors

Sensor Configuration

Sensor configuration is accomplished via TEACH, SET and SETUP modes. After the
sensing parameters are defined (using either TEACH or SET mode), SETUP mode may
be used to enable the delay or to change the light/dark operate status. Manual Adjust
may be used to fine-tune the thresholds (see page 7). Two push buttons, Dynamic
(+) and Static (-), or the remote wire, may be used to access and set the sensing
parameters. The ten-element signal strength bargraph display clearly displays the relative
received signal strength.

Sensor sensitivity may be configured using any of three methods. A single switching
threshold may be achieved using either Dynamic (on-the-fly) or Static TEACH, or Window
SET may be used to define a sensing window, centered on a single sensing condition.

The discrete bipolar (one NPN and one PNP) outputs may be programmed in SETUP
mode to include a 20- or 40-millisecond pulse stretcher (OFF-delay), if required. A
third, dedicated, 0 to 10 milliamp analog output may be used for applications such as
measuring or monitoring of surface brightness or texture.

Both sensing sensitivity and output setup are accomplished either by using the sensor push
buttons, or by supplying input pulses via the remote input.

Remote Configuration

The remote configuration function may be used to configure the sensor remotely or to
disable the push buttons for security. Connect the gray wire of the sensor to ground
(0V dc), with a remote programming switch connected between them. Pulse the remote
line according to the diagrams in the configuration procedures. The duration of the
individual pulses is equal to the value T:

0.04 seconds ≤ T ≤ 0.8 seconds

Returning to RUN Mode

Some TEACH and SET modes may be exited after the 90-second time-out or by exiting
the process:

• In Static TEACH or Window SET mode, press and hold the Static (-) button (or hold the
remote line) for 2 seconds. The sensor returns to RUN mode without saving any new
settings.

SETUP mode may be exited after the 30-second time-out or by exiting the process:

• In SETUP mode, press and hold both the Static (-) and Dynamic (+) buttons (or hold
the remote line) for 2 seconds. The sensor returns to RUN mode and saves the current
setting.

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

P/N 59574 rev. B 3

www.bannerengineering.com • Tel: [phone]

R55 Expert™ Color Mark Sensors

+

DYNAMIC

–

STATIC

+

DYNAMIC

+

DYNAMIC

–

STATIC

–

STATIC

+

DYNAMIC

+

DYNAMIC

–

STATIC

–

STATIC

T

T T

T

T T

T T

T

T

T T

T

T T

T T

T

Sensor positions

threshold midway

between taught conditions

Darkest

(no signal)

Most Light
(saturated

signal)

Output OFF Output ON

2nd Taught

Condition

1st Taught
Condition

Position

adjusted by

Manual Adjust

Static TEACH

• Establishes a single switching threshold

• Threshold position is adjustable using “+” and “-” buttons (Manual Adjust)

Static TEACH is the traditional setup method, used when two conditions can be
presented by the user. The sensor locates a single sensing threshold (the switchpoint)
midway between the two taught conditions, with the Output ON condition on one side,
and the Output OFF condition on the other (see Figure 2).

The first condition taught is the ON condition. The Output ON and OFF conditions can be
reversed by changing Light/Dark Operate status in SETUP mode (see page 7).

Static TEACH and Manual Adjust

Using Manual Adjust with Static TEACH moves the switching threshold. Sensitivity may
be adjusted at any time when the sensor is in RUN mode by clicking the “+” and “-”
buttons. Each click translates to 1/2 segment on the signal strength light bar. For best
sensing reliability, the light and dark conditions should register equally distant from the
switchpoint on the bargraph display.

Push Button

0.04 seconds ≤ “Click” ≤ 0.8 seconds

• Press and hold Static button
≥ 2 seconds until LO and DO
indicators alternately flash,
then release button.

Access

TEACH Mode

• Present the output ON
sensing condition.

• Single-click Static button.

Condition

TEACH Output ON

• No action required; sensor is ready
for 1st TEACH condition.

• Present output ON sensing
condition.

• Single-pulse the remote line.

Remote Line

0.04 seconds ≤ T ≤ 0.8 seconds

Push Button TEACH only:

LO and DO: Alternately flash green

: ON yellow

Light Bar: Goes OFF

LO and DO: Alternately flash green

: OFF

Light Bar: Remains OFF

Figure 2. Static TEACH (Light Operate

shown)

Result

(ready to teach output ON condition)

(ready to teach output OFF condition)

Condition

TEACH Output OFF

NOTES:

1. The sensor will return to RUN mode if either TEACH condition is not registered within 90 seconds. Also, TEACH mode may be cancelled by
pressing and holding the push button for ≥ 2 seconds. In either case, the sensor will revert to the previous conditions taught (i.e., exit without
save).

2. If the sensing conditions are accepted at the end of TEACH Output OFF Condition, the signal strength light bar flashes one of its ten segments
for three seconds to indicate relative sensing contrast. The higher the flashing segment, the higher the measured sensing contrast. High contrast
relates directly to sensing reliability. High-contrast sensing applications are most tolerant of sensing variables, such as web flutter or variations in
color mark color or print density.

4 P/N 59574 rev. B

• Present the output OFF
sensing condition.

• Single-click Static button.

• Wait 0.8 seconds.

• Present the output OFF sensing
condition.

• Single-pulse the remote line.

Contrast accepted: One light bar segment flashes for
three seconds to indicate relative contrast, and then
sensor enters RUN mode.

Contrast too low: Every other segment flashes for three
seconds to indicate low contrast, and the sensor returns
to TEACH Output ON Condition.

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

www.bannerengineering.com • Tel: [phone]