Banner MAXI-AMP Series - Manual (Page 7)

7
Installation and Troubleshooting of CR Series MAXI-AMP Mod-
WIRING TO MODULE: Input, output, and sensor hookup to a MAXI-
AMP module are accomplished using an 11-pole round-pin relay socket. Model
RS-11 is described in detail on page 8.
INPUT POWER REQUIREMENTS: CR Series MAXI-AMP modules
may be powered by AC voltage across terminals #7 and #8. Alternatively, CR
modules may be powered by 12 to 28V dc, with the positive (+) connected to
terminal #3 and the DC common (-) connected to terminal #1.
(NOTE: do not
connect both AC and DC supply voltages.) See specifications and hookup
data on page 2 for more information.
OUTPUT WIRING: The SPDT output relay has a 5-amp rating (see
specifications, page 2). This specification does not forgive the inrush current
demand of AC inductive loads such as solenoids and motor starters. Inrush
current occurs each time an AC inductive load is energized, and is typically ten
times the "holding" current rating of the load. As a result, AC inductive loads
with holding current greater than 1/2 amp (1/10 HP) require an interposing relay.
In addition, an MOV (metal oxide varistor) transient suppressor should be con-
nected across any relay contact that switches an AC inductive load.
For information on the logic level solid-state output at terminal #9 of CR3
models, refer to page 4.
SENSOR WIRING: Miniature remote sensors connect with five wires to
module terminal #1, 2, 3, 10, and 11. Emitters use two wires and receivers use
three wires. Diffuse and convergent models combine emitter and receiver con-
nections into a 5-wire ribbon cable. Sensors are available with 30-foot cables as
an option, and may be wired up to 50 feet away from the MAXI-AMP. 100-foot
lengths of extension cable are available from Banner. All cable splice points
should be soldered. Cables need not be run in conduit; however, in order to
avoid electrical interference, they should be kept as far as possible (at least
several inches) from any high voltage and/or high current wiring.
SENSOR ALIGNMENT:
OPPOSED SENSORS-- visually align the emitter to the receiver. Then secure
the emitter, leaving the receiver loosely mounted. With power applied to the
MAXI-AMP, find the center of the beam by adjusting the receiver up-down-
left-right until the fastest pulse rate is obtained on the "Signal In" status LED. If
necessary, reduce the GAIN control (turn control counterclockwise) to find the
true beam center. When the optimum receiver position has been found (beam
center located), tighten the receiver mounting hardware. (NOTE: it is also pos-
sible to complete the alignment by first securing the receiver in place and then
moving the emitter to find the beam center.) Note that exact optical alignment
is not necessarily the same as optimum mechanical alignment: however, the
difference is usually noticeable only near the maximum range limit or under
conditions of reduced gain.
After aligning the emitter to the receiver, increase the 15-turn GAIN control to
the maximum (fully clockwise) position. Alternately present the "dark" condi-
tion (usually an object breaking the beam) and the "light" condition (usually an
unblocked beam) to the receiver while monitoring the "Signal In" LED:
I
f the "Signal In" LED goes "off' with the "dark" condition and "on" with
the light condition, no further adjustment is necessary.
If the Signal In" LED stays "on" with the "dark" condition, reduce the GAIN
control counterclockwise until the "Signal In" LED just goes "off", then reduce
the control another two full turns. Finally, alternate the "light" and "dark" condi-
tions to ensure that the LED follows the action by turning "on" and "off".
DIFFUSE SENSORS-- No alignment is necessary for diffuse (proximity) mode
sensors, but care must be taken to mount them where no background objects
will be seen, especially when background objects may be more reflective than
the part to be sensed. A good rule is to allow a clear distance behind the part
to be sensed of at least 3 times the sensing distance. When this is not possible,
convergent or opposed sensors must be considered. The best gain setting is
either at maximum setting or two full turns below the point where the "Signal
In" LED just goes "off" in the dark condition (part absent). After setting the
GAIN control, alternate "light" and "dark" conditions to verify that the "Signal
In" LED follows the action by turning "on" and "off".
CONVERGENT SENSORS-- Loosely mount the sensor so that the part to be
sensed will be nominally located at the sensor focus. Present the part to the sensor.
Using the "Signal In" LED, adjust the sensor mounting for the fastest pulse rate,
then tighten the mounting hardware to lock the sensor in that position. Remove
the part and increase the gain (turn control clockwise) either to maximum or to
the point where the "Signal In" LED just turns "on". If the "Signal In" LED turns
"on" before reaching maximum gain, reduce the gain (counterclockwise) until
the "Signal In" LED just turns "off", plus two full turns. Alternate the "light"
condition (part present) and the "dark" condition (part absent) and verify that
the "Signal In" LED follows the action by turning "on" and "off".
NOTE: in any of the sensing modes discussed above, if there is less than
two full turns of the GAIN control between too little gain and too much
gain, try the amplifier's LOW HYSTERESIS mode by turning amplifier pro-
gramming switch #1 to "off". The LOW HYSTERESIS mode should be used
only after exhausting all mechanical measures for increasing optical contrast
(see note, page 5).
TROUBLESHOOTING
If the MAXI-AMP module fails to operate, the following procedure will usu-
ally identify the cause. The procedure, which requires only a VOM, runs as
follows:
1) Remove all wires from the module socket, except for the power supply con-
nections. Measure the supply voltage and compare it to the specified range.
2) Program the module for the factory settings (see page 5) and plug the MAXI-
AMP module into its socket. Set the GAIN control clockwise to at least two
full turns above minimum setting.
3) Using a jumper wire, connect terminal #2 to terminal #10. This simulates
the LIGHT sensing condition. Both the "Signal In" and the "Load Out" LEDs
should come "on".
4) With the jumper wire still in place, switch the module to DARK OPERATE by
turning amplifier programming switch #4 to OFF. The "Signal In" LED should
remain "on" (and pulsing), but the "Load Out" LED should go "off".
5) Remove the jumper wire. The "Signal In" LED should go "off" and the
"Load Out" LED should come "on".
This verifies proper amplifier operation.
If a CR5 model amplifier is involved, the logic functions may be tested using
a jumper wire between terminal #2 and #10 to simulate the LIGHT condition. If
the amplifier checks okay, then test the miniature remote sensor(s) as follows:
1) Connect a VOM (set to the R x 1kΩ scale) to the receiver leads (positive
probe to red wire, "common" probe to black wire). Direct the receiver element
toward a bright light, and alternately expose and cover the lens. The meter should
swing between low impedance (less than 2kΩ) when pointed at a bright light
and high impedance (several megΩ) when completely covered. No response
(unchanging high or low impedance) indicates phototransistor failure.
2) Connect a VOM (set to the R x 1kΩ scale) to the emitter leads (positive probe
to white wire, "common" probe to green wire). The meter should read several
kΩ. Zero ohms or infinite resistance indicates LED failure.
If the sensors(s) check okay, remove power from the module and remove
the module from its socket. Using a VOM (set to any resistance scale) or a
continuity tester, check the continuity of each socket pin receptacle and the
corresponding clamp screw terminal.
If the above steps fail to indicate the cause of trouble, reconnect all wires and
note the trouble symptoms. Contact the Banner Applications Department during
normal business hours at (612) 544-3164 or your local field sales engineer.
WARNING
These photoelectric sensing devices do NOT include the self-checking redundant circuitry necessary to allow their use in
personnel safety applications. A sensor failure or malfunction can result in either an energized or a de-energized output condition.
Never use these products as sensing devices for personnel protection. Their use as safety devices may create an unsafe condition which could
lead to serious injury or death.
Only MACHINE-GUARD and PERIMETER-GUARD Systems, and other systems so designated, are designed to meet OSHA and ANSI machine safety
standards for point-of-operation guarding devices. No other Banner sensors or controls are designed to meet these standards, and they must NOT be used
as sensing devices for personnel protection.