iVu TG Image Sensor

User's Manual

iVu-2010R1
 Table of Contents

1. Product Support and Maintenance........................................................5

1.1 Product Support.........................................................................................................5
1.2 Maintenance..............................................................................................................6

2. Overview of the Sensor...........................................................................7

2.1 Sensor Types.............................................................................................................7
2.2 Typical iVu Applications.............................................................................................8
2.2.1 Label Inspection..............................................................................................8
2.2.2 Blister Pack Inspection ...................................................................................9
2.2.3 Vial Stopper Inspection ...................................................................................9
2.3 Installation................................................................................................................10
2.3.1 Components..................................................................................................10
2.3.2 Mounting the Sensor.....................................................................................12
2.3.3 Cable Connections........................................................................................14
2.4 Overview of Sensor Concepts and Features...........................................................18
2.4.1 Demo Mode...................................................................................................18
2.4.2 Home Screen.................................................................................................18
2.4.3 Triggers.........................................................................................................22
2.4.4 Remote Teach...............................................................................................23
2.4.5 iVu Emulator..................................................................................................23

3. Main Menu Reference............................................................................25

3.1 iVu Main Menu Icons...............................................................................................25
3.2 System Menu...........................................................................................................26
3.2.1 Sensor Type..................................................................................................26
3.2.2 Sensor Configuration.....................................................................................27
3.2.3 Sensor Information........................................................................................28
3.2.4 Lock Sensor...................................................................................................29
3.2.5 Motion............................................................................................................29
3.2.6 Discrete I/O....................................................................................................30
3.2.7 Display Settings.............................................................................................32
3.2.8 Reboot Sensor...............................................................................................33
3.2.9 Firmware Update...........................................................................................33
3.3 Imager Menu............................................................................................................34
3.3.1 Auto Exposure...............................................................................................34
3.3.2 Exposure.......................................................................................................34
3.3.3 Gain...............................................................................................................35
3.3.4 Trigger...........................................................................................................35
3.3.5 Focus.............................................................................................................36
3.3.6 Strobe............................................................................................................36
3.3.7 FOV...............................................................................................................37
3.4 Inspection Menu......................................................................................................38
3.4.1 Match.............................................................................................................38
3.4.2 Area...............................................................................................................40
3.4.3 Blemish .........................................................................................................42
3.4.4 Motion Parameters (Optionally Available for Area and Blemish)..................45
3.5 Logs Menu...............................................................................................................46
3.5.1 Inspection Logs.............................................................................................46
3.5.2 System Logs..................................................................................................48

4. Setting up for an Inspection.................................................................49

4.1 Selecting a Sensor Type..........................................................................................49
4.2 Acquiring a Good Image..........................................................................................49
4.3 Configuring a Match Sensor....................................................................................51

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 4.3.1 Remote Teach...............................................................................................55
4.4 Configuring an Area Sensor....................................................................................55
4.5 Configuring a Blemish Sensor.................................................................................58

5. Debugging Inspections.........................................................................61
5.1 How to Round-Trip Debug Using the Emulator.......................................................61
5.1.1 How to Debug Using the Emulator from a PC...............................................61
5.1.2 How to Debug Using the Emulator from the USB Flash Drive .....................62
5.1.3 How to Debug Using the Emulator from a PC...............................................63
5.1.4 How to Debug Using the Emulator from the USB Flash Drive .....................64

6. Updating the iVu Series Image Sensor................................................65

6.1 How to Update Sensor Firmware............................................................................65
6.2 How to Set or Modify a Sensor Name.....................................................................65
6.3 How to Reset the Sensor Password........................................................................66
6.4 How to Use Bitmap Image Files with the iVu Emulator...........................................67

7. LED Indicator Troubleshooting............................................................69

7.1 Errors.......................................................................................................................69
7.2 Warnings..................................................................................................................70
Product Support and Maintenance 1
This section provides general Banner resources and specific documentation for installers and operators of this
PresencePLUS Vision Sensor.

Warning: Never use this product as a sensing device for personnel protection. Doing so could lead to
serious injury or death. This product does NOT include the self-checking redundant circuitry necessary to
allow its use in personnel safety applications. A sensor failure or malfunction can cause either an energized or
denergized sensor output condition. Consult your Banner Safety Products catalog for safety products that meet
OSHA, ANSI and IEC standards for personnel protection.

1.1 Product Support

Banner provides the following resources for quickly setting up and operating the sensor.
Online Help
PDF Documentation
The documentation is available in a convenient printable format (PDF) on the installation CD or on the Banner Web
site
Banner Website
The most current information available on the Banner website:
www.bannerengineering.com
Warranty Service
The Sensor is designed for reliability. Do not open the housing; it contains no field-replaceable components. If repair
is necessary, do not attempt to repair the sensor yourself; return the unit to the factory. Should it become necessary to
return a sensor to the factory, please do the following:
1. Contact the Banner Factory Application Engineering group at the address or numbers listed below. They will attempt
to troubleshoot the system from your description of the problem. If they conclude that a component is defective,
they will issue an RMA (Return Merchandise Authorization) number for your paperwork and give you the proper
shipping address.
2. Pack the sensor carefully. Damage which occurs during return shipping is not covered by warranty.

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Factory Support
Call, e-mail, fax, or write your local Banner representative or a Banner Applications Engineer for support. Applications
Engineers are available from 8:00 A.M. to 5:00 P.M. Central Time, Monday through Friday, excluding holidays.

Phone Local: 763.544.3164

Toll Free: 1.888.3.SENSOR (1.888.373.6767)

Fax 763.544.3213
E-mail [email protected]
Address Banner Engineering Corp.
9714 10th Avenue North, Minneapolis, MN 55441 USA

To help Banner better assist you, be ready to provide the following information:
• Exact wording of any messages that appeared on your screen
• A description of what you were doing and what happened
• A description of how you tried to solve the problem
• Error Codes (see )

1.2 Maintenance
Maintenance tasks include keeping the hardware free of dust and dirt and possibly updating the as new versions become
available.
Cleaning the Sensor
Regularly remove any dust or dirt from the Sensor using a soft cloth. If needed, slightly dampen the cloth with a weak
solution of neutral detergent. Avoid getting dirt on the imager (the area behind the lens). If the imager is dirty, use
anti-static compressed air to blow off the dust.
Updating the
The current version of is available for download from the Banner website. See Banner Website for the downloads link.
Overview of the Sensor 2
The iVu TG Image Sensor is used to monitor parts for type, size, orientation, shape, and location. No external PC 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 are features of the
iVu sensor:
• Totally self-contained image sensor; no PC required
• No PC required to configure, change or monitor
• Easy configuration: install/connect iVu, select sensor type, acquire image, set inspection parameters
• Advanced capabilities: menu-driven tools guide you as you set up your inspection
• Intuitive interface and sophisticated features make powerful inspection capabilities simple
• On-board language-selectable, intuitive GUI (English, French, German, Italian, Spanish, Japanese, Traditional and
Simplified Chinese)
• Easy configuration: install/connect iVu, acquire image, set inspection parameters
• 68,5 mm touch-screen LCD display (320 x240 pixels)
• Robust IP67 housing with integrated lighting (red, blue, green or infrared)
• M12 connector with 10 to 30 VDC for power supply and PNP or NPN output
• External trigger input, remote TEACH input and external strobe output available
• USB port for upload and download of inspections and log files
• Software emulator for PC available to evaluate inspections offline based on bitmap images
• Compact, rugged housing available with or without a variety of integrated ring lights- red, blue, green, and infrared

2.1 Sensor Types

The iVu Series Image Sensor is actually three sensors in one:
• An Area sensor is used to ensure that some feature, or features, are present on a part. When setting up the sensor for
an Area inspection, some feature, such as a drilled hole, is identified as well as the size (area) expected. If there is
more than one of the identified feature on a part, the number expected can be set as well. During the inspection, the
sensor will verify 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
• A Blemish sensor can be used to find flaws on a part (for example, scratches on a disc), or it can be used to make
sure the a feature exists on a part. Although verifying a feature is present on a part is more commonly an application
for a sensor configured as an Area sensor, a Blemish sensor may be a better option 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
• A Match sensor is used to verify that some pattern, shape, or part orientation matches a reference pattern. The reference
pattern is taught during setup. A reference pattern might include alphanumeric characters, logos, or any other shapes.

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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

Note: The iVu Series Image Sensor can only be one Sensor Type at a time.

2.2 Typical iVu Applications

2.2.1 Label Inspection

A manufacturer packages a number of products in similar packaging and needs a cost-effective way to ensure that only
like products are packaged together. Additionally, they want to verify that all the products have labels.
To verify each product, an iVu Series sensor is configured for a Match inspection. An image of a good product package
is captured. When the inspection is running, if the sensor detects a package with a different or missing label, the sensor
sends a fail output to the line, and the product is rejected.

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2.2.2 Blister Pack Inspection

Because of tightened federal regulations that make the quality of pharmaceutical packaging increasingly critical, when
tablets are inserted into a blister pack, manufacturers need to verify that all the blisters in a pack have been filled with
unbroken tablets.
To verify each blister in the pack, use an iVu Series sensor configured for an Area inspection. The sensor inspects each
blister pack to make sure that each blister contains an unbroken tablet.

2.2.3 Vial Stopper Inspection

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In the pharmaceutical industry where vials are filled with tablets in a high-speed application, as soon as each vial is
filled, a stopper must be properly inserted into the vial.
To ensure that a stopper is properly inserted as each vial leaves the filling station, an iVu Series sensor—set up for an
Area application and motion parameters enabled—verifies that the vial has a stopper inserted into its neck and that the
stopper is positioned correctly to provide a proper seal on the glass vial. If the stopper is missing or incorrectly positioned,
then the sensor sends a fail output to the line.

2.3 Installation

2.3.1 Components

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. You will need to 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 not using an integrated ring light, you will need to have another lighting source. Various lights are available from
Banner. You will also need a triggering source (for example, the Banner WORLD-BEAM® QS18VN6D sensor).

1 Focusing Window
2 Focusing Window Locking Clip
3 LED - Green: Power; Red: Error
4 LED - Green: Pass; Red: Fail

5 Integrated Display

A 8-pin Euro-style (M12) female USB Cable

Connector
B 8-pin Euro-style (M12) male Power and I/O Cable
Connector

C Mounting Bracket Mounting Holes (uses supplied

three M4 x 4 mm screws)

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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, you will need it to set up the sensor
and when you want to monitor inspections.

Note: If not using an integrated ring light, you will need to have another lighting source. Various lights are
available from Banner.

1 Focusing Window
2 Focusing Window Locking Clip
3 LED - Green: Power; Red: Error
4 LED - Green: Pass; Red: Fail

A 8-pin Euro-Style (M12) female Remote Display

connector
B 12-pin Euro-style (M12) male Power and I/O
Cable Connector
C 4-pin Pico (M8) female connector

D Mounting Bracket Mounting Holes (uses supplied

three M4 x 4 mm screws)

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2.3.2 Mounting the Sensor

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

Available iVu Brackets

SMBIVURAL SMBIVURAR SMBIVUU

Mount the sensor securely using one of the brackets above and the three M4 x 4 mm screws that are supplied with the
bracket.

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Installing Filters on the iVu Series Sensor

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

Note: Failure to follow these instructions can cause damage to your iVu Series sensor.

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

1. Use the 1/16" hex key to remove the Focusing Window locking screw (D).

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.
4. Once the is installed, place the Focusing Window back into the housing while inserting the Locking Clip into the
groove as shown below.

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5. Press the Focusing Window onto the housing to make sure that it seats correctly (that is, there is no gap between
the window and housing. Rotate the window counter-clockwise at least two turns.
6. Replace the locking tab screw but do not tighten until you have set up and focused the sensor again.

Caution: Avoid the damage that electrostatic discharget (ESD) can cause to the sensor. Always use a proven
method for preventing electrostatic discharge when installing a lens or attaching a cable.

2.3.3 Cable Connections

Power and I/O Cable Connections for the IVu TG with Integrated Display
Pin # Wire Color Description Direction
2 Brown 10-30V dc Input
7 Blue Common (Signal Input
Ground)
6 Pink External Trigger Input
5 Gray Remote Teach Input
B 1 White Pass/Fail Output
8 Red Ready Output
4 Yellow Strobe Out (5V dc only) Output
3 Green Reserved Output (Do not
connect)

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Cable Connections for the iVu Series Sensors with a Remote Display
The cable connections on the iVu sensor are shown below, and power I/O connections (B) are defined in the Power
I/O Connections table below.

A Remote Display Connector

B Power I/O Connector
C USB Connector

A B

Power I/O Connections

Pin # Wire Color Description Direction
2 Brown 10-30V dc Input
7 Blue Common (Signal Ground) Input
6 Pink External Trigger Input
5 Gray Remote Teach Input
1 White Output 1 Output
8 Red Ready Output
4 Yellow Strobe Out (5V dc only) Output
3 Green Output 2 Output
9 Orange Not used N/A
10 Light Blue RS-232 TX Output
11 Black RS-232 Signal Ground Output
12 Violet RS-232 Rx Input

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I/O Waveforms

PNP Sensor
Below are the iVu PNP sensor waveforms. The PNP sensor triggers from low to high, and Remote Teach behaves
electrically like trigger.

Image Capture

Wire Color Function

Pink Trigger

Remote
Gray Teach

Red Ready

Busy

Output 1
White
(*Pass)

Output 2
Green (*Fail)

Strobe Out
Yellow (Configure as External
& Exposure Based)

* Programmable

NPN Sensor
Below are the NPN sensor waveforms. By default, the NPN version of the sensor triggers from high to low, and Remote
Teach behaves electrically like trigger.

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Image Capture

Wire Color Function

Pink Trigger

Remote
Gray Teach

Red Ready

Busy

Output 1
White
(*Pass)

Output 2
Green (*Fail)

Strobe Out
Yellow (Configure as External
& Exposure Based)

* Programmable

iVu with Integrated Display

By default, the NPN version of the sensor triggers from high to low, and Remote Teach behaves electrically like trigger.
If using an NPN trigger sensor, put a pull-up resistor, rated approximately 1k ohm, between the sensor's positive (+)
voltage and the sensor's input as shown below.

Input Waveforms (iVu with Integrated Display, Firmware Release 1.02 or Earlier)
This section is for users who have deployed the initial release of the iVu firmware (release 1.02). In the intial release
of the iVu sensor, the sensor could be either PNP or NPN, but this referred to the electrical characteristics of the outputs
only. The inputs (trigger and Remote Teach) are described below.

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iVu Trigger and Remote Teach Input Waveforms (iVu with Integrated Display, Release
1.02 or Earlier)
In Release 1.02 or earlier, the iVu Trigger and Remote Teach input waveforms, regardless of model, are shown below.

2.4 Overview of Sensor Concepts and Features

2.4.1 Demo Mode

The first time you power up the iVu Series sensor, it starts in Demo Mode. Demo Mode uses stored images and
inspection parameters that demonstrate how the sensor is set up without having to worry about focus, lighting, or
triggers. In this mode, you can learn how to make adjustments working with the three sensor types while observing
how the adjustments affect the sensor results. To exit Demo Mode, go to Main Menu > System > Sensor Type and
select Exit Demo Mode. When you exit Demo Mode, the sensor reboots into its normal operating mode with default
settings.

2.4.2 Home Screen

The Home screen on the iVu Series sensor display is used to monitor inspections and to configure the sensor. Normally,
the part being inspected is centered on the screen with the feature of interest bounded by the Region of Interest (ROI),
a blue rectangle as shown below. The ROI can be rotated and resized, and is red when selected for adjustment.

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A Main Menu
B Field of View
C Display Modes
D Region of Interest
E Help button
F Zoom In (+) Zoom Out (-)
G Manual Trigger

Main Menu
The Main Menu is used to configure and manage the sensor. It has four sections:
• Inspection, which is where you modify inspection settings
• Imager, which is used to run the Auto Exposure routine and to make adjustments to functions that affect the image
like exposure, gain, trigger, and strobe
• System, which is used to select the Sensor Type and to manage the device
• Logs, which is used to configure and view System and Inspection logs

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System Inspection

Match Percent MatchMatch

Sensor Type Match
Rotation Range
Area
Pass Count
Blemish

Demo Mode Inspection

Motion Number of Edges

Sensor Configuration Save to USB
Sensitivity
Load from USB
Rotation
Reset to Defaults

Match Time Limit*

Area ROI Type
Sensor Information
*When Sensor Type=Match Intensity Range
Lock Sensor
Area Range
Motion
Pass Count
Inspection
Discreet I/O Input Polarity

Output 1
Motion Number of Edges
Output 2
Sensitivity
Display Settings Fail Hold Time
Rotation
Reboot Sensor LCD Timeout

Firmware Update Touch Calibration Blemish ROI Type

Language Sensitivity
Advanced

Edge Length Range

Pass Count

Imager Menu items in gray only display if

Motion is Enabled
Auto Exposure Logs

Exposure
Inspection Logs View Logs
Gain
System Logs Setup
Trigger External

Internal
Locked Sensor
Focus
Free Run Menu Options

Locked
Strobe External

Internal Inspection Logs

System Logs
FOV Maximize FOV
Unlock Sensor
Modify FOV

Figure 1: Main Menu

Field of View
The field of view (FOV) is the area that the sensor can see at a given working distance. The working distance is the
distance from the sensor's lens cover to the part being inspected. By default, the sensor uses the entire FOV in its
operation. The effective FOV can be reduced in order to speed up the processing time of an inspection, or to decrease
background noise.

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Display Modes
The iVu Series sensor has three Display Modes—Annotations Enabled , Annotations Disabled , and Statistics —as
described below.
Annotations Enabled
Annotations Enabled shows the image of the part with hightighting over the pattern or objects that the sensor finds
within the ROI. Green highlighting indicates "good" objects (that is, passes based on all parameter settings); yellow
highlighting indicates "filtered" objects (that is, the object does not meet size requirement or is slightly below the
acceptance level); red highlighting occurs if the sensor can find no object or pattern in the Field of View (FOV) that
matches the reference object or pattern or meets threshold requirements.

Annotations Disabled
Annotations Disabled shows the image of the part without any annotations.

Statistics
Statistics shows Inspection Results and a History that includes information like:

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• Count Range - minimum and maximum number of objects observed

• Passed - running total of parts that passed inspection
• Failed - running total of parts that failed inspection
• Missed - running total of missed triggers
• Inspection Time - time in milleseconds it takes for each inspection to run
• Time Range - minimum and maximum inspection times observed during several triggers
Click the Reset button to reset statistics. Click on the right-arrow in the upper-right title bar to toggle between a display
of History and Inspection Results.

Region of Interest
The region of interest (ROI) is the feature on a part or label that will be evaluated. The ROI is a blue box that can be
resized and rotated as necessary.

2.4.3 Triggers
Trigger A Trigger is a signal that makes the sensor capture an image and inspect it. Use the radio buttons to
select either External Trigger, Internal Trigger or Free Run.

Note: The default is Internal Trigger.

• If Internal Trigger is selected, triggers are based on timed intervals, and you need to select a trigger
interval between 10 and 10000 milliseconds.

Note: If the interval is less than the inspection time, then missed triggers will occur.

• If External Trigger is selected, inspections are triggered in response to an electrical signal on the Trigger
input line.

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• If Free Run is selected, the sensor automatically runs continuous inspections.

2.4.4 Remote Teach

The Remote Teach function is a method of remotely updating inspection parameters while the iVu sensor is running.
Remote Teach is only available when the iVu is configured as a Match sensor. The sequence of events for executing
a Remote Teach as follows:
1. With the sensor Ready, pulse the Remote Teach line.
2. The sensor recognizes that the Remote Teach line has been pulsed and waits for the next valid trigger.
3. At the next valid trigger, Ready goes inactive (the Green Ready LED shuts OFF), and the sensor acquires a new
image.
4. The sensor learns the new pattern and performs the analysis.

2.4.5 iVu Emulator

The iVu Emulator is a Windows application that allows you to operate in a Windows environment exactly as you would
on the iVu Series sensor itself. In general, the Emulator is an inspection debugging tool where you can:
1. Import stored inspections and configuration from an iVu sensor.
2. Modify inspection parameters on the emulator.
3. Restore the updated configuration back to the sensor.

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Main Menu Reference 3

3.1 iVu Main Menu Icons

Main Menu icon — used to access the Main Menu

Inspection icon — provides access to parameters that need to be set for an inspection. Parameters
are dependent on Sensor Type.

Imager icon — lists parameters that affect the characteristics of the captured image.

System icon — used to manage the sensor.

Logs icon — used to set up, view, and save Inspection and System Logs.

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3.2 System Menu

The System menu icon is on the Main Menu, and is used to manage the sensor. The System menu provides for selecting
Sensor Type, updating sensor firmware, backing up and restoring sensor Configuration and other general system-level
operations.

Main Menu > System

3.2.1 Sensor Type

The Sensor Type menu allows you to select one of the following as a Sensor Type:
• An Area sensor that detects if a particular feature (or features) is present
• A Blemish sensor that either detects flaws, or determines if a particular feature (or features) is present when conditions
are not optimal for using an Area sensor
• A Match sensor that determines whether a part or label matches some reference part or label

Note: The first time you start up the sensor, it starts in Demo Mode. Demo Mode uses canned images to demonstrate
how the sensor operates as a Match, Area, and Blemish sensor. If in Demo Mode, Sensor Type will have an option
to exit Demo Mode. If in normal running mode, there is an option to enter Demo Mode.

Main Menu > System > Sensor Type

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3.2.2 Sensor Configuration

The Sensor Configuration menu provides for:
• Saving sensor Configuration to the USB drive
• Restoring sensor Configuration from the USB drive
• Resetting the sensor to defaults
• Updating sensor firmware
• Setting Pass/Fail Output

Main Menu > System > Sensor Configuration

Save to USB
The Save to USB screen provides for saving sensor Configuration to a USB flash drive. The saved configuration
information can be used as a backup or as a way to clone configuration information for other sensors.

Note: On the Emulator, this option is Save Configuration.

Main Menu > System > Sensor Configuration > Save to USB

Load from USB

The Load from USB screen provides for restoring sensor Configuration from a USB drive.

Note: On the Emulator, this option is Load Configuration.

Main Menu > System > Sensor Configuration > Load from USB

Match Time Limit

When the sensor is configured as a Match sensor, this screen provides for adjusting the amount of time alotted for the
sensor to determine if a pattern is good. This is essentially a timeout value. If set too high, the sensor can miss triggers
while trying to match a bad pattern.

Note: This menu option is only available when the Sensor Type selected is Match.

Main Menu > System > Sensor Configuration > Match Time Limit

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Reset to Defaults
Resets all sensor configuration to factory defaults.

Main Menu > System > Sensor Configuration > Reset to Defaults

3.2.3 Sensor Information

The Sensor Information screen displays the following sensor information:
• Serial Number
• Firmware Version
• Boot Number
• Up Timer
• Hour Count
• Model Number
• Sensor Name

Main Menu > System > Sensor Information

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Click the right-arrow next to the Sensor Name field to display a software keyboard that allows you to change the
Sensor Name.

3.2.4 Lock Sensor

This option provides for locking the sensor to prevent accidental modification of settings. When locked, the sensor
only provides access to pass/fail statistics, as well as the ability to view logs and to save them to a USB device. A lock
icon in the upper left corner of the sensor display indicates that the sensor is locked. Note that the sensor can be locked
with or without a password. If a password is not used, unlock the sensor by clicking on the Unlock Device menu. When
a password is used, it must be 4 digits entered using the software keypad. If the password is lost, use the Password
Reset Utility software provided in the CD to obtain a Reset Key.

Note: This menu option is not available on the Emulator.

Main Menu > System > Lock Sensor

3.2.5 Motion
Motion settings involve selecting the number of edges to locate, adjusting sensitivity, and selecting whether or not
rotation is enabled. Motion settings are only available for Area or Blemish sensor types.

Main Menu > System > Motion

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3.2.6 Discrete I/O

The Discrete I/O options are used to adjust iVu input and output settings.

Main Menu > System > Sensor Configuration > Discrete I/O

Input Polarity
The iVu has two input signals—Trigger and Remote Teach. The operation of these signals is dependent on the Input
Polarity setting. Low To High—The Trigger and Remote Teach are detected on a low to high transition of the signal.
High To Low—The Trigger and Remote Teach are detected on a high to low transition of the signal.
The default setting for a PNP sensor is Low To High, and for an NPN sensor it is High To Low. The user can change
the setting on the Input Polarity screen.

Main Menu > System > Sensor Configuration > Input Polarity

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Output 1
Output 1 can be configured for Pass or Fail.
The default setting is Pass and Latched for Output 1. If Pulsed is selected, the default Pulse width is 50 ms.

Note: For Latched the signal is active until the results of an inspection cause a change in the signal output.

Main Menu > System > Sensor Configuration > Discrete I/O > Output 1

Output 2
Output 2, can be configured for Pass or Fail.
The default setting is Fail and Latched for Output 2. If Pulsed is selected, the default Pulse width is 50 ms.

Note: For Latched the signal is active until the results of an inspection cause a change in the signal output.

Main Menu > System > Sensor Configuration > Discrete I/O > Output 2

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3.2.7 Display Settings

The Display Settings menu is for setting the LCD Timeout, the Fail Hold Time, and doing a Touch Screen Calibration.

Main Menu > System > Display Settings

Fail Hold Time

The Fail Hold Time determines how long a failed image is displayed on the LCD so that you can see what failed. The
sensor will continue to process any triggers and the inspection will continue normally. This time delay is just for the
screen. You can set this parameter from 0 to 3600 seconds using the slider at the bottom of the screen.

Main Menu > System > Display Settings > Fail Hold Time

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LCD Timeout
The LCD screen dims after a user-selectable period when it is not being used. Use the arrow keys or slide the bar at
the bottom of the screen to set the LCD screen time out.

Note: This screen is not available on the Emulator.

Main Menu > System > Display Settings > LCD Timeout

Touch Calibration
Touchscreen Calibration may be necessary if the software does not correctly respond when an icon on the screen is
pressed. The calibration routine aligns the touch screen's coordinates to the display behind it. Be sure to follow the
prompts on the screen when executing the Touchscreen Calibration function.

Note: This screen is not available on the Emulator.

Main Menu > System > Display Settings > Touch Calibration

Advanced
Enabling Optimize Display Response helps to make the display more responsive when the sensor is busy (either
inspection times are long and/or no idle time exists between inspections). Disable this feature if Missed Triggers occur
due to touchscreen presses. With this setting disabled, the display may become sluggish when the sensor is busy.

Main Menu > System > Display Settings > Advanced

3.2.8 Reboot Sensor

The Reboot Sensor screen allows you to force a reboot of the sensor.

Note: This option is not available on the Emulator.

Main Menu > System > Reboot Sensor

3.2.9 Firmware Update

The Firmware Update screen is used to load the latest sensor firmware. The Firmware Update screen lists the firmware
versions it finds in the BANNER\FIRMWARE folder on the USB drive. When you receive a firmware update from
Banner Engineering, be sure to put it in the BANNER\FIRMWARE folder on the USB drive.

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Note: The Firmware Update menu is not available on the Emulator.

Main Menu > System > Firmware Update

3.3 Imager Menu

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

Main Menu > Imager

3.3.1 Auto Exposure

Auto Exposure optimizes the exposure time and gain for the current inspection.

Note: The Auto Exposure option is not available on the Emulator.

Main Menu > Imager > Auto Exposure

3.3.2 Exposure
Exposure is the amount of time the sensor allows light to energize the imager. Increasing the exposure time by moving
the slider to the right allows more light to energize the imager, which brightens the image.

Main Menu > Imager > Exposure

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3.3.3 Gain
Gain is an electronic boost to the image signal. Increasing Gain by using the right arrow key or moving the slider to
the right increases image brightness without increasing exposure time. Note that Gain brightens both the light pixels
and dark pixels and may reduce the image quality.

Main Menu > Imager > Gain

3.3.4 Trigger
A Trigger is a signal that makes the sensor capture an image and inspect it. Use the radio buttons to select either
External Trigger, Internal Trigger or Free Run.

Note: The default is Internal Trigger.

• If Internal Trigger is selected, triggers are based on timed intervals, and you need to select a trigger interval between
10 and 10000 milliseconds.

Note: If the interval is less than the inspection time, then missed triggers will occur.

• If External Trigger is selected, inspections are triggered in response to an electrical signal on the Trigger input line.
• If Free Run is selected, the sensor automatically runs continuous inspections.

Main Menu > Imager > Trigger

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3.3.5 Focus
The Focus Number displayed at the bottom of this screen is used to fine-tune image focus. Loosen the lock on the lens
cover, turn the focus ring on the sensor until the Focus Number peaks (or the image appears sharp), then lock the focus
ring.

Note: For the Focus Number to work, the sensor must be triggering and the images must be similar over time.

Main Menu > Imager > Focus

3.3.6 Strobe
The Internal Strobe configures the operation of the integrated ring light. The External Strobe configures the operation
of an external light.

Main Menu > Imager > Strobe

External
The External Strobe is a 5V output that can be used for an external light. Setting options are Always ON, Always
OFF, or Exposure Based. If Exposure Based is selected, then the external light is on during the time the sensor is
capturing an image.

Main Menu > Imager > Strobe > External

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Internal
The Internal Strobe setting configures the operation of the integrated ring light. Setting options are Always ON, Always
OFF, or Exposure Based. If Exposure Based is selected, then the ring light is on during the time the sensor is capturing
an image.

Main Menu > Imager > Strobe > Internal

3.3.7 FOV
The field of view (FOV) is the area that the sensor can see at a given working distance. The working distance is the
distance from the sensor's lens cover to the part being inspected. By default, the sensor uses the entire FOV in its
operation. The effective FOV can be reduced in order to speed up the processing time of an inspection, or to decrease
background noise.

Main Menu > Imager > FOV

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Maximize FOV
If the FOV has been modified and you want to get back to the default quickly, click the Maximize FOV menu option
to restore the FOV to the entire sensor display.

Main Menu > Imager > FOV > Maximize FOV

Modify FOV
Use this option to reduce the size of the FOV.

Main Menu > Imager > FOV > Modify FOV

3.4 Inspection Menu

The Inspection menu icon is located on the the Main Menu, and provides access to parameters that need to be set for
an inspection.

Main Menu > Inspection

3.4.1 Match
When the sensor is configured as a Match sensor, set the ROI Type, Percent Match, Rotation Range, and Pass Count
for the inspection.

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Main Menu > Inspection > Match

ROI Type (Match)

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).

Inspection > Match > ROI Type

Percent Match
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.

Main Menu > Inspection > Match > Percent Match

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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.

Main Menu > Inspection > Match > Rotation Range

Pass Count (Match)

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.

Main Menu > Inspection > Match > Pass Count

3.4.2 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 three parameters:
• Intensity Range (range of gray scale values) of a feature of interest
• Area Range, or size, of a feature of interest
• Pass Count

Main Menu > Inspection > Area

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ROI Type (Area)

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).

Inspection > Area > ROI Type

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 that 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.

Main Menu > Inspection > Area > Intensity Range

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Area Range
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.

Main Menu > Inspection > Area > Area Range

Pass Count (Area)

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.

Main Menu > Inspection > Area > Pass Count

3.4.3 Blemish
When configured as a Blemish sensor, it can be used to find flaws on a part (for example, scratches on a disc), or it
can be used to make sure the a feature exists on a part. Although verifying a feature is present on a part is more commonly
an application for a sensor configured as an Area sensor, a Blemish sensor may be a better option 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

Main Menu > Inspection > Blemish

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ROI Type (Blemish)

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).

Inspection > Blemish > ROI Type

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. 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.

Inspection > Blemish > Sensitivity

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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 hightlighted in
green and those outside the brackets are ignored and colored yellow. You can move each bracket to add or remove
more of the edge segments from consideration.

Inspection > Blemish > Edge Length Range

The range bar at the bottom of the sreen provides a zoomed view of the range so that you can fine-tune the range.
Click on the bar and drag up to bring up the zoomed view as shown below.

Pass Count (Blemish)

The sensor aggregates all the edge pixels that fall within the Edge Length Range and indicates the value with a small
colored bar at the bottom of the Pass Count page. If within the range brackets, the bar is green, otherwise it is yellow.
The brackets can be used to set a tolerance for pass/fail.

Main Menu > Inspection > Blemish > Pass Count

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3.4.4 Motion Parameters (Optionally Available for Area and Blemish)

Motion settings involve selecting the number of edges to locate, adjusting sensitivity, and selecting whether or not
rotation is enabled.

Main Menu > Inspection > Motion

Number of Edges
On the Number of Edges screen, use the radio buttons to select One Edge or Two Edges. If One Edge is selected,
motion is tracked in one direction (by default, horizontally); if Two Edges is selected, motion can be tracked horizontally
and vertically.

Main Menu > Inspection > Motion > Number of Edges

Sensitivity
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.

Main Menu > Inspection > Motion > Sensitivity

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

Main Menu > Inspection > Motion > Rotation

3.5 Logs Menu

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

Main Menu > Logs

3.5.1 Inspection Logs

This menu provides for configuring and viewing Inspection Logs . Inspection Logs are stored inspection records that
include a captured image, the parameters used to inspect it, and the results of that inspection. Up to ten Inspection Logs
can be held in memory on the sensor. The next ten overwrite the previous. Inspection Logs can be saved to the USB
drive so that the logs can be imported to the emulator.

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Main Menu > Logs > Inspection Logs

View Logs
Inspection Logs appear as a strip of film. You can select a frame to view a specific image. Use the icon in the lower
right of the screen to save the logs to the USB drive. Logs saved to the USB drive can be imported into the emulator.
Click the Clear button to clear Inspection Logs.

Main Menu > Logs > Inspection Logs > View Logs

The View Inspection Log screen is used to debug an inspection, and shows one inspection in read-only mode. Click
the upper-left icon to cycle through views. When in Statistics view, the table title has arrows to switch between
Inputs and Results of the Inspection.
Use the left and right arrow keys at the bottom of the screen to navigate through the all stored Inspection Logs.

Setup
Use the radio buttons to Disable Logging, or to log Passed Inspections, Failed Inspections, or All Inspections.

Main Menu > Logs > Inspection Logs > Setup

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3.5.2 System Logs
The System Log contains configuration change information, other notifications, and any errors or warnings that may
be encountered.
• Click the icon in the upper left corner of the screen to show/hide the time column.
• Click Clear Log button at the bottom of the screen to clear the System Log.
• Click the icon at the lower-right of the screen to save the System Log to the USB drive.

Note: System log will not log changes while in Demo mode. Additionally, the Emulator does not log changes.

Main Menu > Logs > System Logs

Setting up for an Inspection 4
In order to set up for an inspection, you need to:
1. Select a Sensor Type.
2. Acquire a good image.
3. Set parameters depending on the Sensor Type.

4.1 Selecting a Sensor Type

When you exit Demo Mode, the sensor reboots as a Match sensor type by default. To change the Sensor Type:
1. Go to Main Menu > System > Sensor Type
This displays the Sensor Type menu options.

2. Select either Area , Blemish, or Matchand click Apply.

3. Click the Home Screen icon in the upper-left corner of the screen to return to the Home screen.

4.2 Acquiring a Good Image

The iVu Series sensor needs to capture a good image of each part to ensure that it correctly passes good parts and fails
bad parts.
1. Go to Main Menu > Imager > Auto Exposure to run the Auto Exposure routine.
2. Check the lighting.
• Make sure that the lighting is constant and consistent (unchanging over time, no shadows or hot spots).
• Capture the shape and form of the target object with lighting that optimizes its contrast and separates it from the
background. Depending on the target, this may mean the integral ring light is not the best choice and other Banner
lights should be considered.
• Adjust the mounting angle to provide the clearest image of the part features you are monitoring. The mounting
bracket lets you easily position and adjust the sensor on your line.
3. If needed, go to Main Menu > Imager > Auto Exposure to run the Auto Exposure routine a second time, or
adjust Gain and Exposure manually:
• Main Menu > Imager > Gain

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• Main Menu > Imager > Exposure

4. Go to Main Menu > Imager > Focus to adjust the focus while monitoring the Focus Number:

a. Use the supplied 1/16" hex key to loosen the Focusing Window locking screw (D), then adjust focus on the iVu
Series sensor using the clear Focusing Window (B).

A Lens

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B Focusing Window
C Locking Clip
D Locking Screw
E Filter Cap (optional)
F Filter (optional)

Note: Filter Kits are available

separately.

b. Adjust focus while monitoring the focus number. To ensure the best image, adjust
the focus until the Focus Number peaks.

Note: Turning the Focusing Window counter-clockwise focuses on closer

objects, while turning the Focusing Window clockwise focuses on more distant
objects.

c. Once the best image has been acquired, lock the focusing window.

4.3 Configuring a Match Sensor

This section describes how to configure a Match sensor using the Demo application as a reference

Note: By default, the Trigger is set to Internal, and will continously trigger based on a time interval setting.
This may make it more difficult to make adjustments while setting up the sensor. The best practice is as follows:
• Go to the Main Menu > Imager > Trigger menu and select External.

• Make sure there is no external trigger input.

• Use the Trigger icon in the lower-right of the screen to manually trigger the sensor to capture an image as you
set up and test.
• Capture images of a range of samples to set up from the "worst" good part to the "best" bad part.

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Start the setup with a good part. Normally, each part to be tested will be centered in the Field of View (FOV).
1. Teach the sensor a good reference part.
a. Adjust the Region of Interest (ROI).The ROI is a blue-dotted box as shown below.

b. Click Anywhere within the ROI to select it. When selected, the ROI is red with resize and rotational icons in
the corners.

c. Resize and move the ROI so that the feature of interest. Resize the ROI so that it surrounds just the feature of
interest. In the Demo example, the feature of interest is the Banner logo as shown below.

Note: When running a Match inspection, the sensor will look for any possible patterns to match anywhere
within the Field of View.

d. Click the Teach icon to teach the sensor this good reference part. With Annotations Enabled, the screen will
highlight in green the pattern found.

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2. Set inspection parameters.

• Adjust the Percent Match parameter. 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.

Note: When running a Match inspection with annotations enabled, the sensor will hightlight in green any
pattern matches that meet or exceed the value specified for Percent Match. Patterns that are below the
specified value for Percent Match (down to approximately 20%), or out of the Rotation Range (see below),
will be colored yellow

1. Using a "bad" part, click the Manual Trigger icon in the lower-right of the screen to capture an image. For
this example, one of the stored images is missing the letter "N," yet the sensor initially sees this as a "good"
label.
2. Go to Main Menu > Inspection, and click the Percent Match option.

3. On the adjustment at the bottom of the screen, adjust the slider and click the Manual Trigger button. When
adjusted correctly, the annotations should turn yellow, and the icon in the upper-right of the screen shouid
indicate fail.

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• Adjust the 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 that the smaller the rotation range, the faster the
inspection will run. To set the Rotation Range:
1. Go to Main Menu > Inspection, and click the Rotation Range option.

2. Move the slider at the bottom of the screen to the desired rotation. If you are verifying that a label is correctly
applied to a container; that is, on straight, you will want to set a small rotation. If you want to make sure that
the correct label is present no matter how the part is oriented in the Field of View, then the rotation range will
be set to its maximum (180°, which is the setting for the Demo).

• Set the Pass Count parameter. 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.
1. Go to Main Menu > Inspection, and click the Pass Count option.

2. Set the Minimum Pass Count and Maximum Pass Count as appropriate. In the Demo, both are set to 1.

3. Test the complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad.

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4. To complete the Match application setup, set triggering as appropriate for your application.

4.3.1 Remote Teach

The Remote Teach function is a method of remotely updating inspection parameters while the iVu sensor is running.
Remote Teach is only available when the iVu is configured as a Match sensor. The sequence of events for executing
a Remote Teach as follows:
1. With the sensor Ready, pulse the Remote Teach line.
2. The sensor recognizes that the Remote Teach line has been pulsed and waits for the next valid trigger.
3. At the next valid trigger, Ready goes inactive (the Green Ready LED shuts OFF), and the sensor acquires a new
image.
4. The sensor learns the new pattern and performs the analysis.

4.4 Configuring an Area Sensor

This section describes how to configure an Area sensor using the Demo application as a reference

Note: By default, the Trigger is set to Internal, and will continously trigger based on a time interval setting.
This may make it more difficult to make adjustments while setting up the sensor. The best practice is as follows:
• Go to the Main Menu > Imager > Trigger menu and select External.

• Make sure there is no external trigger input.

• Use the Trigger icon in the lower-right of the screen to manually trigger the sensor to capture an image as you
set up and test.
• Capture images of a range of samples to set up from the "worst" good part to the "best" bad part.

Start the setup with a good part. Normally, each part to be tested will be centered in the Field of View (FOV).
1. Adjust the Region of Interest (ROI).The ROI is a blue-dotted box as shown below.

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2. Click Anywhere within the ROI to select it. When selected, the ROI is red with resize and rotational icons in the
corners.

3. Resize and move the ROI so that the feature of interest. Resize the ROI so that it surrounds just the feature of
interest. In the Demo example, the feature of interest is the Banner logo as shown below.

Note: When running an Area inspection, the sensor will only find objects within the ROI.

4. Click anywhere outside the ROI to deselect it.

5. Set inspection parameters.
• Adjust the Intensity Range parameter. 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 that 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.
1. Go to Main Menu > Inspection, and click the Intensity Range option.

2. Click on the eye-dropper icon on the left of the screen, and then click anywhere in one of the white letters.
Now any white area will be highlighted in green. 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 and counts.

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The objects colored yellow are found, but filtered out (that is, not counted) because the objects fall outside of
the Area Range.

• Adjust the Area Range. 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.
1. Go to Main Menu > Inspection, and click the Area Range option.

2. Move the slider at the bottom of the screen to the to the desired area range. In the Demo example, the Area
Range is adjusted so that each letter is identified as a found object (indicated by the green hightlights and the
blue +).

• Set the Pass Count parameter. 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.
1. Go to Main Menu > Inspection, and click the Pass Count option.

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2. Set the Minimum Pass Count and Maximum Pass Count as appropriate. In the Demo, both are set to 6,
since the inspection should find six letters.

6. Test the complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad.
7. To complete the Area application setup, set triggering as appropriate for your application.

Note: Remote Teach does not work with the Area Sensor type.

4.5 Configuring a Blemish Sensor

This section describes how to configure a Blemish sensor using the Demo application as a reference. The Demo
application shows how the sensor, when configured as a Blemish tool, can accept or reject parts based on the range of
edge pixels the sensor detects in the ROI.
Start the setup with a good part. Normally, each part to be tested will be centered in the Field of View (FOV).
1. Adjust the Region of Interest (ROI).The ROI, when selected, is a red box as shown below.

Resize the ROI so that the feature of interest. Resize the ROI so that it surrounds just the feature of interest. In the
Blemish Demo example, the feature of interest includes the two irregular shapes below the Banner logo.
2. Click anywhere outside the ROI to deselect it.
3. Set inspection parameters.
• Adjust the Sensitivity parameter. 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. 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.
1. Go to Main Menu > Inspection, and click the Sensitivity option.

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2. Use the slider on the bottom of the screen to adjust the sensitivity watching as the sensor detects more or fewer
edges.
3. Click the Trigger button on the bottom-right of the screen to see how the sensor detects edges on other images,
and adjust if necessary.

• Adjust the 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 hightlighted in green and those outside the brackets are ignored and colored yellow. You
can move each bracket to add or remove more of the edge segments from consideration.
1. Go to Main Menu > Inspection, and click the Edge Length Range option.

2. Move the slider at the bottom of the screen to the to the desired Edge Length Range. You can zoom in to refine
the range.

Banner Engineering Corp. Minneapolis, MN USA 59

 • Set the Pass Count parameter. The sensor aggregates all the edge pixels that fall within the Edge Length Range
and indicates the value with a small colored bar at the bottom of the page. If within the range brackets, the bar is
green, otherwise it is yellow.
1. Go to Main Menu > Inspection, and click the Pass Count option.

2. Use the brackets to set a tolerance for the pass/fail.

4. Test the complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad.
5. To complete the Blemish application setup, set triggering as appropriate for your application.

Note: Remote Teach does not work with the Blemish Sensor type.
Debugging Inspections 5

5.1 How to Round-Trip Debug Using the Emulator

The iVu Emulator is a Windows application that allows you to operate in a Windows environment exactly as you would
on the sensor itself. In general, the Emulator is an inspection debugging tool: you can import stored inspections and
configuration from an iVu sensor, then modify its parameters on the emulator, and restore the updated configuration
back to the sensor. When you install the iVu Emulator, by default, it is installed in the following folder:
C:\Program Files\Banner Engineering\iVu Series
You can run the Emulator from this folder, but you will need to move files between the USB drive and PC. To avoid
moving files, you can copy the Emulator executable to the USB drive, and run the Emulator directly from the USB
drive.
This "how-to" describes the procedures for doing round-trip debugging either using the iVu Emulator installed on a
PC or using it directly from the USB Thumb Drive

Note: This document refers to saving configuration and inspection logs in folders based on the sensor name. If
you have not yet named the sensor, then folders will be named using the first 8-characters of the sensor serial
number.

5.1.1 How to Debug Using the Emulator from a PC

1. Plug a USB Thumb Drive into the sensor.
2. Save Inspection Logs to the Thumb Drive.
a. On the Main Menu > Inspection Logs > View Logs screen, click the Save icon to save the inspection logs.
b. When prompted, select Yes to save sensor configuration along with the Inspection Logs. The locaton of these
files on the USB Thumb Drive will be displayed after the operation is completed. The Inspection Logs are saved
in <USB>:\BANNER\<SENSOR_NAME>\InspLog and the sensor configuration is saved in
<USB>:\BANNER\<SENSOR_NAME>. For example, if the sensor name is myName:
• Configuration File (CONFIG.CFG) path: <USB>:\BANNER\myName
• Inspection Logs path: <USB>:\BANNER\myName\InspLog

Note: If the sensor has no name, then the folder is the first 8-characters of the serial number.

3. Remove the USB drive from the sensor and insert it into an available USB port on a Windows PC that has the iVu
Emulator installed.

Important: Make sure the iVu Emulator is NOT running before going to the next step.

4. Copy the Sensor Configuration from the USB Thumb Drive to the folder where the Emulator is installed on the
PC. For example, if the sensor name is myName and the iVu Emulator is installed in the default location on the
PC, copy the file <USB>:\BANNER\myName\CONFIG.CFG to C:\Program Files\Banner Engineering\iVu Series.
5. Copy the Inspection Logs from the USB Thumb Drive (for example, <USB>:\BANNER\myName\InspLog) to the
InspLog folder on the PC (for example, C:\Program Files\Banner Engineering\iVu Series\InspLogs).
6. Start the emulator.

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Debugging Inspections 2/2010

7. Set the Trigger option to Internal—

a. Go to Main Menu > Imager > Trigger, and select Internal.
b. Set the Trigger Interval as desired.
The iVu Emulator will run with the saved configuration from Step 6 using the saved Inspection Logs from Step
7 as images.

8. Make the desired adjustments.

9. Close the iVu Emulator program. All configuration changes will be saved to the CONFIG.CFG file.
10. Copy the sensor configuration (that is, CONFIG.CFG) from the PC working directory to the USB Thumb Drive
(for example <USB>:\BANNER\myName\CONFIG.CFG).
11. Remove the USB Thumb Drive from the PC, and connect to the sensor.
12. Restore the configuration to the sensor.
a. Go to Main Menu > System > Sensor Configuration > Load from USB.
b. Select the Configuration to restore.
c. Click the Load button to start the restore sensor configuration.
You will need to reboot the sensor when the restore is complete.

5.1.2 How to Debug Using the Emulator from the USB Flash Drive
1. Plug a USB Thumb Drive into the sensor.
2. Save Inspection Logs to the sensor.
a. On the Main Menu > Inspection Logs > View Logs screen, click the Save icon to save the inspection logs.
b. When prompted, select Yes to save sensor configuration along with the Inspection Logs. The location of these
files on the USB Thumb Drive will be displayed after the operation is completed—the Inspection Logs are
saved in <USB>:\BANNER\<SENSOR_NAME>\InspLog and the sensor configuration is saved in
<USB>:\BANNER\<SENSOR_NAME>. For example, if the sensor name is myName:
• Configuration File (CONFIG.CFG) path: <USB>:\BANNER\myName
• Inspection Logs path: <USB>:\BANNER\myName\InspLog

Note: If the sensor has no name, the the folder name is the first 8-characters of the serial number.

3. Remove the USB drive from the sensor and insert it into an available USB port on a Windows PC that has the iVu
Emulator installed.
4. Copy the iVuEmulator.exe program file to the USB Thumb Drive in the same location as the CONFIG.CFG file
(for example, <USB>:\BANNER\myName).
5. Launch the <USB>:\BANNER\myName\iVuEmulator.exe program.
6. Set the Trigger option to Internal—
a. Go to Main Menu > Imager > Trigger, and select Internal.
b. Set the Trigger Interval as desired.
The iVu Emulator will run with the saved configuration using the saved Inspection Logs as images.

7. Make the desired adjustments.

8. Close the iVu Emulator program. All configuration changes will be saved to the CONFIG.CFG file.
9. Remove the USB Thumb Drive from the PC, and connect to the sensor.
10. Restore the configuration to the sensor.
a. Go to Main Menu > System > Sensor Configuration > Load from USB.
b. Select the Configuration to restore.

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2/2010 Debugging Inspections

c. Click the Load button to start the restore sensor configuration.

You will need to reboot the sensor when the restore is complete.

5.1.3 How to Debug Using the Emulator from a PC

1. Plug a USB Thumb Drive into the sensor.
2. Save Inspection Logs to the Thumb Drive.
a. On the Main Menu > Inspection Logs > View Logs screen, click the Save icon to save the inspection logs.
b. When prompted, select Yes to save sensor configuration along with the Inspection Logs. The locaton of these
files on the USB Thumb Drive will be displayed after the operation is completed. The Inspection Logs are saved
in <USB>:\BANNER\<SENSOR_NAME>\InspLog and the sensor configuration is saved in
<USB>:\BANNER\<SENSOR_NAME>. For example, if the sensor name is myName:
• Configuration File (CONFIG.CFG) path: <USB>:\BANNER\myName
• Inspection Logs path: <USB>:\BANNER\myName\InspLog

Note: If the sensor has no name, then the folder is the first 8-characters of the serial number.

3. Remove the USB drive from the sensor and insert it into an available USB port on a Windows PC that has the iVu
Emulator installed.

Important: Make sure the iVu Emulator is NOT running before going to the next step.

4. Copy the Sensor Configuration from the USB Thumb Drive to the folder where the Emulator is installed on the
PC. For example, if the sensor name is myName and the iVu Emulator is installed in the default location on the
PC, copy the file <USB>:\BANNER\myName\CONFIG.CFG to C:\Program Files\Banner Engineering\iVu Series.
5. Copy the Inspection Logs from the USB Thumb Drive (for example, <USB>:\BANNER\myName\InspLog) to the
InspLog folder on the PC (for example, C:\Program Files\Banner Engineering\iVu Series\InspLogs).
6. Start the emulator.
7. Set the Trigger option to Internal—
a. Go to Main Menu > Imager > Trigger, and select Internal.
b. Set the Trigger Interval as desired.
The iVu Emulator will run with the saved configuration from Step 6 using the saved Inspection Logs from Step
7 as images.

8. Make the desired adjustments.

9. Close the iVu Emulator program. All configuration changes will be saved to the CONFIG.CFG file.
10. Copy the sensor configuration (that is, CONFIG.CFG) from the PC working directory to the USB Thumb Drive
(for example <USB>:\BANNER\myName\CONFIG.CFG).
11. Remove the USB Thumb Drive from the PC, and connect to the sensor.
12. Restore the configuration to the sensor.
a. Go to Main Menu > System > Sensor Configuration > Load from USB.
b. Select the Configuration to restore.
c. Click the Load button to start the restore sensor configuration.
You will need to reboot the sensor when the restore is complete.

Banner Engineering Corp. Minneapolis, MN USA 63

5.1.4 How to Debug Using the Emulator from the USB Flash Drive
1. Plug a USB Thumb Drive into the sensor.
2. Save Inspection Logs to the sensor.
a. On the Main Menu > Inspection Logs > View Logs screen, click the Save icon to save the inspection logs.
b. When prompted, select Yes to save sensor configuration along with the Inspection Logs. The location of these
files on the USB Thumb Drive will be displayed after the operation is completed—the Inspection Logs are
saved in <USB>:\BANNER\<SENSOR_NAME>\InspLog and the sensor configuration is saved in
<USB>:\BANNER\<SENSOR_NAME>. For example, if the sensor name is myName:
• Configuration File (CONFIG.CFG) path: <USB>:\BANNER\myName
• Inspection Logs path: <USB>:\BANNER\myName\InspLog

Note: If the sensor has no name, the the folder name is the first 8-characters of the serial number.

3. Remove the USB drive from the sensor and insert it into an available USB port on a Windows PC that has the iVu
Emulator installed.
4. Copy the iVuEmulator.exe program file to the USB Thumb Drive in the same location as the CONFIG.CFG file
(for example, <USB>:\BANNER\myName).
5. Launch the <USB>:\BANNER\myName\iVuEmulator.exe program.
6. Set the Trigger option to Internal—
a. Go to Main Menu > Imager > Trigger, and select Internal.
b. Set the Trigger Interval as desired.
The iVu Emulator will run with the saved configuration using the saved Inspection Logs as images.

7. Make the desired adjustments.

8. Close the iVu Emulator program. All configuration changes will be saved to the CONFIG.CFG file.
9. Remove the USB Thumb Drive from the PC, and connect to the sensor.
10. Restore the configuration to the sensor.
a. Go to Main Menu > System > Sensor Configuration > Load from USB.
b. Select the Configuration to restore.
c. Click the Load button to start the restore sensor configuration.
You will need to reboot the sensor when the restore is complete.
Updating the iVu Series Image Sensor 6

6.1 How to Update Sensor Firmware

Banner Engineering may release new versions of the sensor firmware in the future. New firmware releases can be
downloaded from Banner's website (http://www.bannerengineering.com) or can be obtained by ordering the latest
Product CD. The following steps will guide you through the process of updating the iVu firmware from the Product
CD:
1. Place the Product CD into your CD ROM drive.
2. Plug a Banner-approved USB Thumb Drive into an available USB port on your PC.
3. Create a new folder called BANNER\FIRMWARE on the root directory on the USB Thumb Drive. For example,
if the Thumb Drive letter is F: then
a. Create a folder called BANNER.
b. Open the F:\BANNER folder.
c. Create a folder called FIRMWARE.
You should now have a F:\BANNER\FIRMWARE folder on your USB Thumb Drive.
4. Browse to the FIRMWARE folder on the product CD (for example, if your CD ROM drive is E:, then browse to
the E:\FIRMWARE folder).
5. Copy the new firmware binary (for example, IVU_V110.BIN) to the <USB>\BANNER\FIRMWARE folder on
the USB Thumb Drive.
6. Remove the USB Thumb Drive from the PC, and plug it into the sensor.
7. On the sensor, select System > Sensor Configuration > Firmware Update. A list of firmware files contained in
the <USB>\BANNER\FIRMWARE folder on the USB flash drive will be displayed.
8. Choose the version of the firmware to be installed on the sensor.
9. Follow the steps on the screen to update the firmware. A reboot of the sensor will be required after the update.

6.2 How to Set or Modify a Sensor Name

You can set a Sensor Name for your iVu Series sensor or modify an existing name on the sensor using the software
keypad. You can also change the sensor name this using the iVu Emulator as described below.

Note: If you are in a language other than English, you cannot modify the sensor name using the software keypad.
Use the procedure described below.

Note: If you have not set the sensor previously, then folders will be named using the first 8-characters of the
sensor serial number.

1. Plug a USB Thumb Drive into the sensor.

2. Save Sensor Configuration to the USB Thumb Drive (Main Menu > System > Sensor Configuration > Save to
USB). The locaton of these files on the USB Thumb Drive will be displayed after the operation is complete—the
sensor configuration is saved in <USB>:\BANNER\<SENSOR_NAME>. For example, if the sensor name is
myName:, the path will be <USB>:\BANNER\myName).
3. Remove the USB drive from the sensor and insert it into an available USB drive on a Windows PC.

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Updating the iVu Series Image Sensor 2/2010

4. If running the Emulator from the USB, launch the iVuEmulator.exe program. If running the Emulator installed on
a PC, make sure the Emulator is not running, and copy the Sensor Configuration from the USB Thumb Drive to
the folder where the Emulator is installed on the PC. For example, if the sensor name is myName and the iVu
Emulator is installed in the default location on the PC, copy the file <USB>:\BANNER\myName\CONFIG.CFG
to C:\Program Files\Banner Engineering\iVu Series.
5. Launch the iVuEmulator.exe program.
6. Go to the Sensor Information screen (Main Menu > System > Sensor Information).
7. Click the white box next to the Sensor Name label, and enter the desired Sensor Name.
8. Click the Back button on the lower-left corner of the screen to save the Sensor Name.
9. Close the Emulator program and the Sensor Name will be saved to the CONFIG.CFG file.
10. If running the Emulator on the PC, copy the CONFIG.CFG file back to the original folder on the USB
drive—<USB>:\BANNER\<SENSOR_NAME> (for example <USB>:\BANNER\myName).

Note: The sensor will look in the original folder (for example, myName) for the CONFIG.CFG file.

11. Remove the USB Thumb Drive from the PC, and connect to the sensor.
12. Restore the configuration to the sensor.
a. Go to Main Menu > System > Sensor Configuration > Load from USB.
b. Select the Configuration to restore.
c. Click the Load button to start the restore sensor configuration.

Note: Once the new sensor name is restored in the sensor, all files saved to USB will now reside in the
folder corresponding to the new sensor name.

You will need to reboot the sensor when the restore is complete.

Note: If a Sensor Configuration from one sensor is loaded onto another sensor, the Sensor Name from the Sensor
Configuration will not be stored in the sensor.

6.3 How to Reset the Sensor Password

If you forget the password for your sensor, you can remove the current password using a reset key that is generated by
the Password Reset Utility, which is located on the Product CD. The following steps will guide you through the
specific steps to reset the password:
1. On your iVu Series sensor, click the Forgot? button located on the bottom of the Enter Current Password screen.
2. Write down the 6-digit Device Key.
3. On a Windows PC, insert the iVu product CD into the CD ROM drive.
4. From the product CD menu (started upon inserting the CD), launch the Password Reset Utility.
5. Enter the Device Key into the text box in the Utility—identified as Step 1 in the Password Reset Utility.
6. Click the Generate Reset Key button.
7. Write down the four-digit Password Reset Key—identified as Step 2 in the Password Reset Utility.
8. On the iVu Series sensor, check the Next button on the Password Reset screen.
9. Enter the 4-digit reset key on the Enter Reset Key screen.
10. Click Apply.
The password is now cleared.

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2/2010 Updating the iVu Series Image Sensor

6.4 How to Use Bitmap Image Files with the iVu Emulator
You can use bitmap (.bmp) image files with the iVu Emulator for developing and simulating iVu inspections. The iVu
Emulator only accepts image files in .bmp format. If you have other image file formats, use an image viewer/editor
program, such as PhotoShop, Gimp, or Paint, to convert the files to 8-bit grayscale .bmp format.

Note: Images smaller than 640 X 480 will be black-filled starting in the upper-right. Images larger than 640 X
480 will be cropped starting in the upper-left.

1. Copy the .bmp files into the InspLog folder in the iVu Emulator install folder.
For example, copy .bmp files into the C:\Program Files\Banner Engineering\iVu Series\InsLog folder.

Note: Remove any existing .bmp or Log files in that folder to avoid confusion because the Emulator
automatically runs all .bmp/Log files sequentially according to filename.

2. Launch the iVu Emulator program.

3. Select Internal Trigger on the Trigger Selection screen (Main Menu > Image > Trigger) and select Internal.
4. Set the Trigger Interval as desired.
The iVu Emulator will be running using the .bmp files from Step 1.

Note: Banner does not recommend setting up inspections using these 8-bit grayscale images because you will
always end up modifying the configuration after loading it on the sensor on the line. A better choice would be to
set up the inspection on the emulator using Inspection Logs from the sensor.

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Updating the iVu Series Image Sensor 2/2010

68 Minneapolis, MN USA Banner Engineering Corp.

LED Indicator Troubleshooting 7
In normal operation, the Power LED is steady green, and the Pass/Fail is green or red depending on the triggered
inspection.

1
Green: Power
Red: Error

2
Green: Pass
Red: Fail

The iVu also indicates abnormal conditions as described below.

7.1 Errors
Problem Indicator Solution
The Pass/Fail LED is blinking green a number Reboot the sensor.
of times, separated by an LED red blink, and
the sensor repeats this pattern over and over.
This indicates that no inspections are
occurring.
The Power LED is lit steady red. These type Do the following:
of errors are reported in the System log and
1. Look in the System Log to see the error.
appear highlighted in red.
2. Clear the LED; that is, go to the Main Menu > Logs > System
Logs and press the Clear System Error button at the bottom of the
screen (a sensor reboot is not required).
3. If the error occurs again, you can try rebooting the sensor to see if
that fixes the problem. If the problem persists, contact Banner
customer support.

Banner Engineering Corp. Minneapolis, MN USA 69

7.2 Warnings
Warnings are atypical conditions that the sensor detects and fixes. Warning are highlighted in yellow in the System
Log, and can typically be ignored.
Index
A I
Advanced 33 imager
annotations disabled 21 auto exposure 34
annotations enabled 21 exposure 34
area parameters gain 35
area range 42, 57 trigger 22, 35
intensity range 41, 56 imager menu 34
area range 42, 57 Inspection Logs 46
area sensor 40 inspection menu 38
Area sensor 26 intensity range 41, 56
auto exposure 34 internal strobe 37
iVu emulator 61, 63
B
L
blemish sensor 42
Blemish sensor 26 LCD Timeout 33
Load from USB 27
lock sensor 29
D logs
debugging 61, 63 inspection 46
demo mode 18 system 48
display modes 21
annotations disabled 21 M
annotations enabled 21
statistics 21 main menu 19
Display Settings menu 32 match parameters
percent match 39, 53
rotation range 40, 54
E match sensor 38
emulator 61, 63 Match sensor 26
exposure 34 Match Time Limit 27
external strobe 36 maximum pass count 40, 42, 54, 57
menu
Display Settings 32
F Sensor Configuration 27
Sensor Type 26
fail hold time 32 System 26
field of view 20, 37 minimum pass count 40, 42, 54, 57
firmware update 33 motion parameters
focus number 36 area range 42, 57
intensity range 41, 56
G motion settings 29, 45
number of edges 45
gain 35 rotation 46
sensitivity 45
motion settings 29, 45
H
home screen 18 N
number of edges 45
P Sensor Type menu 26
statistics 21
pass count parameter 40, 42, 54, 57 strobe
percent match 39, 53 external 36
internal 37
System Logs 48
R System menu 26
region of interest 22
ROI 22 T
rotation parameter 46
rotation range 40, 54 Touchscreen Calibration 33
trigger 22, 35
S
U
Save to USB 27
sensitivity 45 USB
Sensor Configuration menu 27 loading from 27
sensor display 18 saving to 27
Sensor Information 28