Banner R55F Fiber Optic User Manual

R55F Series Fiber-Optic Color Mark Sensors

For Plastic and Glass Fiber Optics

Printed in USA

05/01 P/N 57945 rev. B

R55F Series Sensor Features

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

• Depending on beam color, reliably detects the toughest color mark contrasts,
including 20% yellow against white.

• Fast, 50-microsecond response.

• Choose from infrared or one of four visible beam colors: red, blue, green and
white.

• Fibers mount in small and otherwise inaccessible areas.

• Easy push-button programming options include Static TEACH, Static Single-Point
TEACH, Dynamic TEACH and Remote TEACH; plus manual sensitivity adjustment.

• Non-volatile memory.

• Glass fiber models function well in harsh environments typically associated with
printing processes.

• Plastic fiber models function well in applications that require repeated flexing of
the fibers.

• Fibers install quickly without tools.

• Bipolar (NPN/PNP) outputs with three Delay settings (0, 20 or 40 milliseconds).

• Choice of integral cable or QD connector models.

• Mounts flat or to 35 mm DIN rail; two brackets included with sensor (one for
angle mount, one for flat mount).

R55F Series Sensor Overview

The R55F Fiber-Optic Sensor was developed to provide simplicity of operation and
access to tight areas for color mark (registration) sensing applications. The R55F is a
technological advancement from earlier R55 models.

R55F sensors feature TEACH mode sensitivity adjustment, by presenting the light and
the dark sensing conditions to the sensor. In addition, sensitivity may be fine-tuned at
any time by simply clicking the “+” or “-” buttons on the sensor. The ten-element signal
strength light bar clearly displays the relative received signal strength.

The bipolar (one NPN and one PNP) outputs may be programmed to include a 20 or
40-millisecond pulse stretcher (OFF Delay), if required. Both TEACH mode sensitivity
adjustment and output SETUP are accomplished using the push-buttons on the sensor,
or by supplying input pulses via the Remote Teach input.

TEACH mode has two options: Static TEACH and Dynamic TEACH. Static TEACH is
used to manually set the two sensing conditions individually or to program a specific
condition to be sensed (single-point TEACH). Dynamic TEACH provides a means for
teaching a series of conditions on-the-fly; the R55F “averages” the sensing events and
automatically sets (and periodically updates via the adaptive threshold feature) the
switch point between light and dark conditions.

R55F Series Fiber-Optic Color Mark Sensors

page

2

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

www.bannerengineering.com • Tel: [phone]

R55F Series Glass Fiber-Optic Sensor Models

R55F Series Plastic Fiber-Optic Sensor Models

* 9m (30') cables are available by adding suffix “W/30” to the model number of any cabled sensor (e.g., R55FV W/30). A model with a QD

connector requires a mating cable (see page 11).

Advantages of glass fiber optics for color mark sensing:

• Randomly mixed bifurcated fiber bundles produce the best optics for color mark sensing.

• Bundle of small fibers may be shaped at sensing end tip to match the color mark shape.

• Best chemical resistance.

Visible Red, 650 nm
Visible Green, 525 nm
Visible Blue, 475 nm
Visible White, 450-650 nm
Infrared, 880 nm

Visible Red, 650 nm
Visible Green, 525 nm
Visible Blue, 475 nm
Visible White, 450-650 nm

Advantages of plastic fiber optics for color mark sensing:

• Plastic fibers may be repeatedly flexed.

• Low cost.

• Most models may be cut to fit in the field.

Model

Number

Maximum Sensing Distance

For black-to-white contrast

Cable*

Supply

Voltage

Output

Type

Visible Red, 650 nm

10 to 30V dc

Bipolar
NPN/PNP

R55FP

0.040" dia. Fibers: 60 mm (2.4")

5-wire 2 m (6.5') cable

R55FPQ 5-pin Euro-style QD
Visible Green, 525 nm
R55FPG

0.040" dia. Fibers: 28 mm (1.1")

5-wire 2 m (6.5') cable

R55FPGQ 5-pin Euro-style QD
Visible Blue, 475 nm
R55FPB

0.040" dia. Fibers: 28 mm (1.1")

5-wire 2 m (6.5') cable

R55FPBQ 5-pin Euro-style QD
Visible White, 450 - 650 nm
R55FPW

0.040" dia. Fibers: 28 mm (1.1")

5-wire 2 m (6.5') cable

R55FPWQ 5-pin Euro-style QD

Model

Number

Maximum Sensing Distance

For black-to-white contrast

Cable*

Supply

Voltage

Output

Type

Visible Red, 650 nm

10 to 30V dc

Bipolar
NPN/PNP

R55FV

0.060" dia. Bundle: 28 mm (1.1")

0.125" dia. Bundle: 110 mm (4.3")

5-wire 2 m (6.5') cable

R55FVQ 5-pin Euro-style QD
Visible Green, 525 nm
R55FVG

0.060" dia. Bundle: 12 mm (0.5")

0.125" dia. Bundle: 50 mm (2.0")

5-wire 2 m (6.5') cable

R55FVGQ 5-pin Euro-style QD
Visible Blue, 475 nm
R55FVB

0.060" dia. Bundle: 12 mm (0.5")

0.125" dia. Bundle: 50 mm (2.0")

5-wire 2 m (6.5') cable

R55FVBQ 5-pin Euro-style QD
Visible White, 450 - 650 nm
R55FVW

0.060" dia. Bundle: 12 mm (0.5")

0.125" dia. Bundle: 50 mm (2.0")

5-wire 2 m (6.5') cable

R55FVWQ 5-pin Euro-style QD
Infrared, 880 nm
R55F

0.060" dia. Bundle: 40 mm (1.6")

0.125" dia. Bundle: 140 mm (5.5")

5-wire 2 m (6.5') cable

R55FQ 5-pin Euro-style QD

R55F Series Fiber-Optic Color Mark Sensors

page

3

Banner Engineering Corp. •

Minneapolis, U.S.A.

www.bannerengineering.com • Tel: [phone]

B

Figure 1. Installing fibers into the R55F

Series sensor

Plastic fibers
shown; procedure
is identical for
glass fibers

Glass Fiber Installation Procedure:

1) Check to see that a rubber o-ring is pre-installed on each fiber control end.

2) Slide the fiber clip to the open position (A).

3) Insert one fiber end into each port (B). Push firmly on the fiber ends to compress
the o-rings and align the grooves in the fiber ends with the slot in the fiber clip.

4) Slide the fiber clip back into place, locking the fibers into position (C).

Plastic Fiber Installation Procedure:

NOTE: R55F sensors accept 0.75, 1.0, and 1.5 mm (0.03", 0.04", and 0.06") core

diameter plastic fibers.

1) Cut the “control ends” (sensor ends) of the plastic fiber(s) to the desired length
per the procedure which accompanies the fiber assembly.

2) If not already done, separate bifurcated fibers by approximately 2" from the control
ends.

3) Slide the fiber clip to the open position (A).

4) Insert the fiber ends into each port and push them in as far as they will go (B).

5) Slide the fiber clip back into place, locking the fibers into position (C).

Fiber Optic Mounting Considerations

Mount the sensing end of the fiber optic assembly so that the light image is totally
contained within the boundaries of the color mark to be sensed. The light image is
made smaller by moving the sensing tip closer to the surface of the material to be
sensed.

When sensing marks on shiny (specular) materials, such as metal, plastic or glossy
paper, mount the sensing tip of the fiber at approximately 15° from perpendicular to
the material surface to minimize strong direct reflections.

Isolate the fiber mounting from vibration. Also, maintain mechanical stability of the
surface to be sensed (e.g., stabilize web flutter at the sensing point).

Fiber
Clip

C

A

R55F Series Fiber-Optic Color Mark Sensors

page

4

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

www.bannerengineering.com • Tel: [phone]

Using the R55F Series Sensor

RUN Mode

Normal operation of the R55F is called RUN mode. The LED indicators (see
Figure 2) operate as follows in RUN mode:

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 Light Bar: indicates signal strength, with respect to the sensing
threshold (“Switch Point”).

TEACH Modes

The sensitivity of the R55F may be quickly optimized by using one of two available TEACH modes: Static TEACH or Dynamic
TEACH. Either may be performed using the push buttons on the sensor, or remotely, using a remote switch or process controller

connected to the sensor’s gray wire(see page 8).Either a sensing window or a specific point may be taught.

Static TEACH

In Static TEACH mode, the sensor learns the light condition and the dark condition, each one time. Sensitivity is automatically set
to place the switch point midway between the two conditions. In addition, the condition taught first becomes the output ON
condition.

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 switch point on the signal strength light bar.

Single-Point TEACH

The R55F sensor also may be taught a single specific target, using an alternate Static TEACH procedure. The sensor will sense
only the mark taught and will ignore signals both stronger and weaker. The sensitivity to the taught mark then may be adjusted up
or down.

To perform single-point TEACH, place the target in front of the sensor. Press and hold the “Static” button until the LO and DO
LEDs begin to flash, then double-click the Static button. If the single point was successfully taught, the two center sections of the
bar graph will flash.

Manually adjust the sensitivity by clicking either the “+” or “-” button; the bar graph will flash two segments centered about the
sensing point. If the sensitivity is increased (-), the two lighted segments will become closer together, and farther apart if the
sensitivity is decreased (+). If the segments do not flash while the sensitivity is being adjusted, the setting has reached its
maximum and cannot be adjusted further.

Figure 2. R55F Series sensor features

Output

Conducting

LED

Delay
Configuration
Indicator LED

(Light Operate)

(Dark Operate)

* Either LO or DO LED is ON
whenever sensor has power
and is in RUN mode

LO

LED*

DO

LED*

Dynamic
TEACH (+)
Push Button

10-Segment
Light Bar

Switch
Point

Static
TEACH (-)
Push Button