Baumer PosCon3D User manual

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Contents
1 General information......................................................................................................................4
1.1 Concerning the contents of this document.....................................................................................4
1.2 Intended use...................................................................................................................................4
1.3 Safety notes....................................................................................................................................4
2 Commissioning in 4 steps ...........................................................................................................5
2.1 Connection......................................................................................................................................5
2.2 Installation.......................................................................................................................................6
2.3 Measuring mode.............................................................................................................................7
2.4 Measurement................................................................................................................................10
2.5 Optional settings...........................................................................................................................10
3 Connection..................................................................................................................................11
3.1 Connection cable..........................................................................................................................11
3.2 Pin assignment and connection diagram......................................................................................12
4 Installation...................................................................................................................................13
4.1 Mounting.......................................................................................................................................13
4.2 Sensor reference levels................................................................................................................13
4.3 The reference surface...................................................................................................................14
4.4 Sensor alignment..........................................................................................................................15
4.5 Standard installation .....................................................................................................................16
4.6 Angled installation.........................................................................................................................18
4.7 Blind region...................................................................................................................................19
4.8 Practical zero point search ...........................................................................................................20
4.9 Installation accessories.................................................................................................................20
5 Configuration via touch panel...................................................................................................22
5.1 Overview of control elements .......................................................................................................22
5.2 Function tree.................................................................................................................................25
5.3 LIVE MONITOR............................................................................................................................27
5.4 MEAS TYPE .................................................................................................................................28
5.5 EDGE HEIGHT / OBJECT HEIGHT / GAP DEPTH .....................................................................32
5.6 OBJECT........................................................................................................................................32
5.7 PRECISION..................................................................................................................................32
5.8 FLEX MOUNT...............................................................................................................................34
5.9 FIELD OF VIEW ...........................................................................................................................38
5.10 DIGITAL OUT................................................................................................................................43
5.11 SYSTEM.......................................................................................................................................44
5.12 SETTINGS....................................................................................................................................45
6 Function and definition..............................................................................................................47
6.1 Datasheet......................................................................................................................................47
6.2 Dimensions...................................................................................................................................49
6.3 Functional principle.......................................................................................................................50
6.4 Object to be measured .................................................................................................................52
6.5 Interfaces and outputs..................................................................................................................54
6.6 Touch panel...................................................................................................................................58
6.7 Memory.........................................................................................................................................58
7 Safety instructions and maintenance.......................................................................................59
7.1 General safety instructions...........................................................................................................59

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7.2 Laser class....................................................................................................................................59
7.3 Influence of ambient light..............................................................................................................59
7.4 Front (optics).................................................................................................................................59
7.5 Cleaning the sensors....................................................................................................................60
8 Error correction and tips............................................................................................................60
8.1 Effects of deviations in the inclination angle.................................................................................60
8.2 Error correction.............................................................................................................................61
9 Change history............................................................................................................................63

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1 General information
1.1 Concerning the contents of this document
This manual contains information about the installation and commissioning of Baumer PosCon 3D edge
sensors. Article number 11111452, article name: OXE7.E25T-11111452
It is a supplement to the mounting instructions supplied with each sensor.
1.2 Intended use
The Baumer PosCon 3D sensor detects edges and outputs their position, distance, and center between
edges.
It was especially developed for easy handling, flexible use, and precise measurement. The red light laser
ensures that the light beam is always visible, which makes sensor alignment easier and minimizes installation
errors. The sensor operates without a reflector.
1.3 Safety notes
NOTE
Provides helpful operating instructions or other general recommendations.
ATTENTION!
Indicates a possibly hazardous situation. If it is not avoided, minor or slight injuries
can occur or the device can be damaged.
Read these operating instructions carefully and follow the safety instructions!

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2 Commissioning in 4 steps
After the sensor is connected and installed, configure it via the display, selecting either the "Edge", "Width" or
"Gap" function and performing the other application-specific settings/measurement type within these
functions. Afterward the sensor is ready for operation and outputs the measuring value in mm to the screen.
Optionally, the measuring field can be limited or the switching output can be configured.
Connection
Installation
Function Edge Function Width Function Gap
Let's get started
Optional: Measuring field limitation
Optional: Switching output
2.1 Connection
Connection
Connect the sensor according to the connection
diagram. A shielded connection cable (8-pole M12)
must be used.
When everything is correctly connected, the sensor
starts up and the display lights up.
Key functions
ESC = Back
ESC 2 sec. = Main menu
UP = Up/increase value
DOWN = Down/decrease value
SET = OK
SET 2 sec. = Save value
Slide over all 4 keys:
----> = Enables the panel if locked
<---- = Jump to run mode
Setting the language
The language will be selected and confirmed by
pressing SET for 2 seconds.
English
Deutsch
Italiano
Français
1
1
2
3
4
5
6

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2.2 Installation
Standard installation
In standard installation, the sensor is mounted at a
right angle to the reference surface or the object. The
sensor is not taught into the reference surface so
configuration is very easy and straightforward.
This installation method is recommended even if the
reference surface cannot be taught in for some
reason or another.
Angled installation
In angled installation, the sensor can be mounted
at an angle of up to +/- 30° in relation to the
reference surface. This installation method is used
when space conditions do not allow any other
installation option or the mounting angle is not
known.
Align the sensor as accurately as possible at a right
angle to the reference surface (background) or to the
object (if there is no reference surface in the
measuring field). The object must be within the
measuring field, i.e. the distance from the sensor
must be between 150 and 250 mm.
The sensor may be mounted at an angle inclined
maximally 30° to the left or to the right of the
reference surface (background) or to the object (if
there is no reference surface in the measuring
field).
The reference surface (background) or the object
must be within the measuring field, i.e. the
distance from the sensor must be between 150
and 250 mm.
2
NOTE
The "Edge L rise or Edge R rise" mode can be used as an aid to find the zero point.
Now an object is slowly pushed toward the presumed zero point. The zero point is
reached by the left rising edge of the object when the value 0 mm is shown on the
sensor display and the yellow LED switches..
0 mm
+62.5 mm
@250 mm
-62.5 mm
@250 mm
right
left
150 mm
<100 mm
Measuring
field
0 mm
+54.6 mm
@250 mm
-73.0 mm
@250 mm
right
left
0 mm
150 mm
Measuring
field
+/
-
30°
<100 mm
Reference surface

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2.3 Measuring mode
EDGE: Edge (basic setting)
To perform edge measurement, select FUNCTION
EDGE in the menu. Within EDGE the edge to be
measured is defined in MEAS TYPE.
EDGE L RISE = First rising edge from the left
EDGE L FALL = First falling edge from the left
EDGE R RISE = First rising edge from the right
EDGE R FALL = First falling edge from the right
EDGE L RISE EDGE L FALL
EDGE R RISE EDGE R FALL
EDGE HEIGHT
Minimum height to be detected as an edge.
OBJECT
Selection of light or dark objects to optimize the
measurement results.
PRECISION
To achieve better precision and resolution, it is
possible to alternate between Standard, High and
Very High by filtering the output values.
FLEX MOUNT
If the sensor is mounted at an angle, FLEX
MOUNT must be activated and the reference
surface must be taught in.
1. Activate FLEX MOUNT
2. Align and confirm sensor or reference
surface
3. When all conditions are met (see table on
right), confirm by pressing Set for 2 seconds
4. Enter thickness of the auxiliary plate (if
present)
Distance between sensor and
reference surface
Installation angle too large
Reference surface too uneven
Reference surface too small
(<50 mm)
3a
Min. edge height
Object
Reference

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WIDTH: Width measurement
To perform width measurement, select FUNCTION
WIDTH in the menu. In WIDTH the desired output is
selected in the MEAS TYPE menu.
WIDTH = Distance between the first rising
flank from the left and the first
rising flank from the right.
CENTER WIDTH = Center between the first rising
flank from the left and the first
rising flank from right in relation to
the measuring axis of the sensor.
WIDTH CENTER WIDTH
OBJECT HEIGHT
Minimum height of the object to be measured.
OBJECT
Selection of light or dark objects to optimize the
measurement results.
PRECISION
To achieve better precision and resolution, it is possible to
alternate between Standard, High and Very high by
filtering the output values.
FLEX MOUNT
If the sensor is mounted at an angle, FLEX MOUNT must
be activated and the reference surface must be taught in.
1. Activate FLEX MOUNT
2. Align and confirm sensor or reference surface
3. When all conditions are met (see table on right),
confirm by pressing Set for 2 seconds
4. Enter thickness of the auxiliary plate (if present)
Distance between sensor
and reference surface too
long
Installation angle too
large
Reference surface too
uneven
Reference surface too
small (<50 mm)
3b
Min. object height
Object
Reference

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GAP: Gap
measurement
To perform gap measurement, select FUNCTION GAP in
the menu. In GAP the measurement type to be activated
is defined in the MEAS TYPE menu.
GAP = Distance between the first
falling flank from the left and the
first falling edge from the right.
CENTER GAP = Center between the first falling
flank from the left and the first
falling flank from right in relation
to the measuring axis of the
sensor.
GAP CENTER GAP
GAP DEPTH
Minimum gap depth to be detected as an edge.
OBJECT
Selection of light or dark objects to optimize the
measurement results.
PRECISION
To achieve better precision and resolution, it is possible to
alternate between Standard, High and Very high by
filtering the output values.
FLEX MOUNT
If the sensor is mounted at an angle, FLEX MOUNT must
be activated and the reference surface must be taught in.
1. Activate FLEX MOUNT
2. Align and confirm sensor or reference surface
3. When all conditions are met (see table on right),
confirm by pressing Set for 2 seconds
4. Enter thickness of the auxiliary plate (if present)
Distance between sensor
and reference surface
Installation angle too large
Reference surface too
uneven
Reference surface too
small (<50 mm)
3c
Min. gap depth
Object
Reference

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2.4 Measurement
2.5 Optional settings
Measuring field limitation
(optional)
The measuring field can be changed via the
FIELD OF VIEW function. This function is
required when there are objects in the
measuring field which should not be detected.
- AUTO for limitation with a rectangle of
automatic size
- Separate configuration of the single
points of the field
LIMIT LEFT, LIMIT RIGHT, OFFSET
Switching output
(optional)
The sensor is equipped with a switching output
that can be configured as a point or as a
window via the DIGITAL OUTPUT function.
Let's get started
The sensor continuously outputs the measuring
value in mm to the display and transmits it via
the analog output to the control. Alternatively,
the measuring value can also be retrieved from
the RS485 interface.
4
5a
5b
LIMIT LEFT
LIMIT RIGHT
OFFSET
Left Right Left Right
Point Window

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3 Connection
3.1 Connection cable
An 8-pole, shielded connection cable (connector) is required.
Baumer connection cables with the following order codes are recommended:
•ESG 34FH0200G (length 2 m, straight plug)
•ESW 33FH0200G (length 2 m, angled plug)
Other cable lengths are available.
ATTENTION!
Laser class 1 laser beam according to EN 60825-1:2007. This product can be
operated safely without any additional safety precautions. Nevertheless direct
contact
between the eye and beam should be avoided.
ATTENTION!
The IP protection class is valid only if all connections are connected as
described in the technical documentation.
ATTENTION!
Connection, installation and commissioning may only be performed by qualified
personnel.
ATTENTION!
Incorrect supply voltage will destroy the device!

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3.2 Pin assignment and connection diagram
Color
Function
Description
Pin 1 WH = white Rx/Tx- RS 485 receive/transmit- (B)
Pin 2 BN = brown + Vs Voltage supply (+15…+28 VDC)
Pin 3 GN = green analog Output analog (4…20 mA or 0…10V)
Pin 4 YE = yellow out Switch-out, push-pull
Pin 5 GY = gray alarm Alarm-out, push-pull
Pin 6 PK = pink Rx/Tx+ RS485 receive/transmit+ (A)
Pin 7 BU = blue 0V Ground GND
Pin 8 RD = red sync in Input synchronization
NOTE
It is recommended to connect unused inputs to GND (0V).

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4 Installation
4.1 Mounting
The sensor has four mounting holes for flexible alignment and mounting. The use of 2 M4x35 screws is
recommended for mounting; the tightening torque is max. 1.2 Nm.
4.2 Sensor reference levels
To ensure easy alignment of the sensor during installation, the surfaces defined here are available:
The laser beam of the sensor runs parallel ( // ) to level R3 and is at a right angle to levels R1 and R2. Levels
R1, R2, and R3 serve as a reference for sensor alignment during installation. The terms "Left" and "Right" are
also important here. Also important are the terms "Left" and "Right".
19 mm
Level R3
Laser
beam
Level R1
Level R2
13 mm
ATTENTION!
Connection, installation and commissioning may only be performed by qualified
personnel. Protect optical surfaces from moisture and dirt.
Left Right

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4.3 The reference surface
The measuring level where the object to be detected is located is referred to as the reference surface. It
should be as even as possible; there must not be any edges in the measuring field which should not be
detected (for exceptions see Section MEASURING FIELD).
If no reference surface is available as a measuring level (next background/edge > 250 mm away from sensor
level R2), the sensor should be aligned to the object.
If the PosCon 3D sensor cannot be aligned at a right angle to the reference surface, the FLEX MOUNT
function should be activated.
Reference surface
Object
Object axis
NOTE
The reference surface…
•can be within the measuring field (but doesn't have to be)
•must not have any edges in the sensor measuring range
•should be as even as possible
•can be taught in with the FLEX MOUNT function

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4.4 Sensor alignment
As standard the sensor is mounted at a right angle (90°) to the reference surface or the object (standard
installation), but it can also be mounted at an angle of up to ±30° (angled installation).
To get the most accurate measurement results possible in angled installation, the inclination angle of the
sensor has to be taught in, see Section FLEX MOUNT.
The distance from the reference surface or the object must not exceed 250 mm on the measuring axis.
NOTE
To facilitate sensor alignment, the LIVE MONITOR can be used as an aid. LIVE
MONITOR continuously outputs the currently measured angle and the distance
from the reference surface.
NOTE
Angle deviations can affect measuring accuracy (see Section Alignment errors).

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4.5 Standard installation
In standard installation, the sensor is mounted at a right angle (90°) to the reference surface or the object
(when there is no reference surface).
To Reference Surface To Object

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4.5.1 Definition of the measuring field with standard installation
The important terms "Left" and "Right" are to be regarded respectively from the viewpoint of the connector.
-37.5 mm
0 mm
12 mA / 5 V +62.5 mm
18.25 mA / 8.12 V
250 mm
0 mm
100 mm
Measuring
field
X
Z
+37.5 mm
-62.5 mm
5.75 mA / 1.87 V
Blind region
Reference
point
The sensor measures objects and edges
at a distance of 150 … 250 mm (z axis)
and in the measuring range (x axis) from
-62.5 mm to +62.5 mm (at a distance of
250 mm).
The object must be within the measuring
field, i.e. the distance must not exceed
250 mm, but it can also be smaller.
Note
On the analog output:
For further explanations, see
Section "Function and definition“ -
> "Interfaces and outputs" ->
"Analog signal output".
Measuring
axis
Right
Left

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4.6 Angled installation
Compared to standard installation, the sensor can be mounted at an arbitrary inclination angle up to ±30°.
This is particularly useful when space conditions do not allow any other installation option. See also Section
FLEX MOUNT. The object must be within the measuring field.
4.6.1 Definition of the measuring field with angled installation
At the maximum allowable inclination angle of ±30°, the sensor measures objects and edges within the
measuring field defined below. The important terms "left" and "right" are to be regarded respectively from the
connector side of the sensor. After activating the FLEX MOUNT function the axes M and K now represent the
measurement coordinate system and no longer the sensor axis. The measured value is now the distance from
one object-edge to the M-axis.
0 mm
0…-30°
+30…0°
0 mm
250 mm
K
M
Reference surface
Measuring
field
-73.0 mm
+54.6 mm
0 mm
0 mm
250 mm
K
M
Measuring
field
-68.8 mm
+57.3 mm
Example with -30° inclination
angle
Example with -20° inclination angle
Blind region Blind region
Reference point Reference point
K
M

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4.7 Blind region
The 0 … 150 mm range (distance from the sensor) is the blind region, i.e. the sensor cannot detect any edges
there.
Nevertheless the placement of objects there should be avoided because the shadowing of objects can create
a fictitious edge which is detected by the sensor and results in the output of an incorrect measuring value.
0 mm
0 mm
0 mm
250 mm
K
M
Measuring
field
-67.0 mm
+58.6 mm
0 mm
250 mm
K
M
Measuring
field
-65.4 mm
+59.9 mm
Example with -15° inclination
angle
Example with -10° inclination
angle
Blind region Blind region
Reference point Reference point
250 mm
100 mm
Blind region

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4.8 Practical zero point search
In case of angled installation, the zero point (0 mm) of the K axis shifts out of the center of the red visible laser
line.
4.9 Installation accessories
To ensure optimal mounting, various mounting brackets are available an as accessory. These brackets fit the
mounting holes of the sensor exactly. The sensor can be shifted and adjusted inside the mounting hole.
4.9.1 Mounting kit for standard installation Order no. 11120705
With the mounting bracket for standard installation, the sensor can be mounted quickly and easily at a 90°
angle to the reference surface.
Mounting kit 11120705
Contents of this set:
- 90° mounting bracket
- Threaded plate
- 2x spherical head screw M4x35
- 1x Torx tool T20
-
NOTE
The "Edge L rise or Edge R rise" mode can be used as an aid to find the zero point.
Now an object is slowly pushed toward the presumed zero point. The zero point is
reached by the left rising edge of the object when the value 0 mm is shown on the
sensor display and the yellow LED switches.