LMI Gocator 2000 Family User manual

User’s ManUal Gocator 2000 Family
Version 2.2.1.0 Revision: A

2Gocator 2000 Family
Copyright © 2011 by LMI Technologies, Inc. All rights reserved.
Proprietary
This document, submitted in confidence, contains proprietary information which shall not be reproduced
or transferred to other documents or disclosed to others or used for manufacturing or any other purpose
without prior written permission of LMI Technologies Inc.
No part of this publication may be copied, photocopied, reproduced, transmitted, transcribed, or
reduced to any electronic medium or machine readable form without prior written consent of
LMI Technologies, Inc.
Trademarks and Restrictions
Gocator™ is a registered trademark of LMI Technologies, Inc. Any other company or product names
mentioned herein may be trademarks of their respective owners.
Information contained within this manual is subject to change.
This product is designated for use solely as a component and as such it does not comply with the
standards relating to laser products specified in U.S. FDA CFR Title 21 Part 1040.
Contact Information
For more information, please contact LMI Technologies.
LMI Technologies, Inc.
1673 Cliveden Ave.
Delta, BC V3M 6V5
Canada
Telephone: [phone]
Facsimile: [phone]
www.lmi3D.com

3Gocator 2000 Family
Introduction
The Gocator 2000 Family of laser profiling sensors are designed for 3D measurement and control
applications. Gocator sensors are configured using a web browser and can be connected to a variety of
input and output devices. This guide describes the installation and use of Gocator sensors.
Notational Conventions
This guide uses the following notational conventions:
!
Warning Follow these safety guidelines to avoid potential injury or property damage.
Note Consider this information in order to make best use of the product.

4Gocator 2000 Family
Introduction 3
Table of Contents 4
Safety and Maintenance 7
Laser Safety 7
Laser Classes 8
Precautions and Responsibilities 9
Class 3B Responsibilities 9
Systems Sold or Used in the USA 10
Electrical Safety 11
Environment and Lighting 12
Sensor Maintenance 12
Getting Started 13
System Overview 13
Standalone System 13
Dual Sensor (Buddy) System 14
Multi-Sensor System 15
Hardware 16
Sensor 16
Master 200 17
Master 400/800 18
Master 1200/2400 19
Cordsets 20
Calibration Targets 21
Installation 22
Grounding - Standalone / Master 200 22
Grounding - Master 400/800/1200/2400 22
Mounting 22
Installation Orientations 24
Software 26
User Interface Overview 26
Connecting to a New Sensor 27
Running a Sensor for the First Time 29
Customizing Network Settings 30
Assigning a Buddy 31
Updating Firmware 32
Next Steps 33
Setup 34
Setup Page 35
Saving and Loading Settings 36
Recording and Playback 38
Table of Contents
Coordinate Systems 40
Metrics Panel 41
Operation Modes and Data Viewers 42
Profile Output in Profile and Raw Mode 44
Connection Type 45
Trigger 46
Active Area 49
Single Exposure 50
Multiple Exposure 52
Dynamic Exposure 53
Resolutions 54
Filtering 55
Transformations 56
Dual Sensor Layout 57
Calibration 58
Calibration States 58
Alignment vs. Travel Calibration 58
Alignment Calibration 59
Travel Calibration 60
Clearing Calibration 61
Measurement 62
Measurement Page 65
Adding and Removing Measurements 66
Changing a Measurement’s Name 67
Measurement ID 68
Profile Sources 69
Feature Points 70
Fit Lines 72
Compare Profile 73
Decisions 74
Profile Fixturing 75
Measurement Types 77
Width 77
Height 78
Distance 79
Position X 80
Position Z 81
Center X 82
Center Z 83
Angle X 84
Intersect X 85
Intersect Z 86
Intersect Angle 87
Intersect Area 88
Box Area 89
Difference Area 90
Difference Peak 91

5Gocator 2000 Family
Script 92
Output 94
Output Page 94
Ethernet Input/Output 95
Digital Outputs 96
Analog Output 98
Dashboard 101
State and Health Information 101
Measurement Statistics 102
Management and Recovery 103
Security 104
Managing Files 105
Working with Backups 106
Recovering Sensors 107
Auto Starting of Sensors 108
Ethernet Protocol 109
Concepts 110
Discovery 110
Command Channels 110
Result Channels 110
Modes 111
Buddy Communication Channels 111
States 111
Versions and Upgrades 111
Data Types 112
Profile Sources 112
Status Codes 112
Command and Reply Formats 113
Result Format 113
Configuration Files 115
Setup 122
ProfileMeasurement 125
Outputs 131
Calibration File 134
SysCal 135
Discovery Commands 136
Get Address 136
Set Address 137
Upgrade Commands 138
Get Protocol Version 138
Start Upgrade 138
Get Upgrade Status 138
Get Upgrade Log 139
Control Commands 140
Get Protocol Version 140
Get System Info 140
Log In/Out 141
Change Password 142
Change Buddy 142
Get File List 142
Copy File 143
Read File 143
Write File 143
Delete File 144
Get Default File 144
Set Default File 145
Get Loaded File 145
Get Mode 145
Set Mode 146
Get Time 146
Get Encoder 146
Start 147
Scheduled Start 147
Stop 147
Trigger 148
Scheduled Digital Output 148
Scheduled Analog Output 148
Ping 149
Reset 149
Backup 149
Restore 150
Restore Factory 150
Set Connection Type 151
Get Connection Type 151
Data Results 152
Video 152
Profile 152
Alignment Calibration 153
Travel Calibration 153
Exposure Calibration 153
Measurement 154
Health Results 155
Serial Protocol 157
Connection Settings 157
Message Format 158

6Gocator 2000 Family
Software Development Kit 159
Troubleshooting 160
Mechanical/Environmental 160
Connection 160
Laser Profiling 160
Performance 161
Specification 162
Gocator sensors 162
Gocator 2020 163
Gocator 2030 165
Gocator 2040 167
Gocator 2050 169
Gocator 2070 171
Gocator 2080 173
Gocator I/O Connector 175
Grounding Shield 175
Power 175
Laser Safety Input 176
Digital Outputs 177
Digital Inputs 178
Encoder Input 178
Serial Output 179
Analog Output 179
Master 200 180
Master 400/800 182
Master 400/800 Electrical Specifications 183
Master 1200/2400 184
Master 1200/2400 Electrical Specifications 185
Parts and Accessories 186
Warranty and Return Policy 188
Warranty Policy 188
Return Policy 188
Software Licenses 189
Software Licenses 189
Support 193
Support 193

7Gocator 2000 Family
Safety and Maintenance
Laser Safety
Gocator sensors contain semiconductor lasers that emit visible
light and are designated as Class 2M, Class 3R, or Class 3B,
depending on the chosen laser option.
Gocator sensors are referred to as components, indicating that
they are sold only to qualified customers for incorporation into
their own equipment. These sensors do not incorporate safety
items that the customer is required to provide in their own
equipment (e.g. remote interlocks, key control). As such, these
sensors do not fully comply with the standards relating to laser
products specified in IEC 60825-1 and FDA CFR Title 21 Part
1040.
Use of controls or adjustments or performance of procedures other than those specified herein
may result in hazardous radiation exposure.
References
1. International standard IEC 60825-1 (2001-08) consolidated edition, Safety of laser products – Part
1: Equipment classification, requirements and user’s guide.
2. Technical report 60825-10, Safety of laser products – Part 10. Application guidelines and
explanatory notes to IEC 60825-1.
3. Laser Notice No. 50, FDA and CDRH http://www.fda.gov/cdrh/rad-health.html
LASER
SENSOR
WARNING: DO NOT LOOK DIRECTLY
INTO THE LASER BEAM
LASER

Safety and Maintenance • 8Gocator 2000 Family
Laser Classes
Class 2M laser components
Class 2M laser components would not cause permanent
damage to the eye under reasonably foreseeable
conditions of operation, provided that any exposure
can be terminated by the blink reflex (assumed to take
0.25 seconds). Because classification assumes the
blink reflex, the wavelength of light must be in the visible
range (400 nm to 700 nm). The Maximum Permissible
Exposure (MPE) for visible radiation for 0.25 seconds is
25 watts per square meter, which is equivalent to 1 mW
entering an aperture of 7 mm diameter (the assumed
size of the pupil).
IEC 60825-1:2007
LASER RADIATION
DO NOT STARE INTO THE BEAM
OR VIEW DIRECTLY WITH OPTICAL
INSTRUMENTS OR MAGNIFIERS
CLASS 2M LASER PRODUCT
PEAK POWER:
EMITTED WAVELENGTH:
This product is designated for use solely as a
component and as such it does not fully comply
with the standards relating to laser products
specified in U.S. FDA CFR Title 21 part 1040
and IEC 60825-1
1 mW
660 nm
Class 3R laser components
Class 3R laser products emit radiation where direct
intrabeam viewing is potentially hazardous, but the
risk is lower with 3R lasers than for 3B lasers. Fewer
manufacturing requirements and control measures for
3R laser users apply than for 3B lasers.
IEC 60825-1:2007
LASER RADIATION
AVOID DIRECT EYE EXPOSURE
CLASS 3R LASER PRODUCT
PEAK POWER:
EMITTED WAVELENGTH:
This product is designated for use solely as a
component and as such it does not fully comply
with the standards relating to laser products
specified in U.S. FDA CFR Title 21 part 1040
and IEC 60825-1
5 mW
660 nm
Class 3B laser components
Class 3B components are unsafe for eye exposure.
Usually only ocular protection will be required. Diffuse
reflections are safe if viewed for less than 10 seconds.
IEC 60825-1:2007
LASER RADIATION
AVOID EXPOSURE TO THE BEAM
CLASS 3B LASER PRODUCT
PEAK POWER:
EMITTED WAVELENGTH:
This product is designated for use solely as a
component and as such it does not fully comply
with the standards relating to laser products
specified in U.S. FDA CFR Title 21 part 1040
and IEC 60825-1
130 mW
660 nm
Labels reprinted here are examples only. For accurate specifications, refer to the label on your sensor.

Safety and Maintenance • 9Gocator 2000 Family
Precautions and Responsibilities
Precautions specified in IEC 60825-1 and FDA CFR Title 21 Part 1040 are as follows:
Requirement Class 2M Class 3R Class 3B
Remote interlock Not required Not required Required*
Key control Not required Not required Required – cannot remove
key when in use*
Power-on delays Not required Not required Required*
Beam attenuator Not required Not required Required*
Emission indicator Not required Not required Required*
Warning signs Not required Not required Required*
Beam path Not required Terminate beam at useful
length
Terminate beam at useful
length
Specular reflection Not required Prevent unintentional
reflections
Prevent unintentional
reflections
Eye protection Not required Not required Required under special
conditions
Laser safety officer Not required Not required Required
Training Not required Required for operator and
maintenance personnel
Required for operator and
maintenance personnel
*LMI Class 3B laser components do not incorporate these laser safety items. These items must be added and completed by the
customer in their system design.
Class 3B Responsibilities
LMI Technologies has filed reports with the FDA to assist customers in achieving certification of laser
products. These reports can be referenced by an accession number, provided upon request. Detailed
descriptions of the safety items that must be added to the system design are listed below.
Remote Interlock
A remote interlock connection must be present in Class 3B laser systems. This permits remote switches
to be attached in serial with the keylock switch on the controls. The deactivation of any remote switches
must prevent power from being supplied to any lasers.
Key Control
A key operated master control to the lasers is required that prevents any power from being supplied to
the lasers while in the OFF position. The key can be removable in the OFF position but the switch must
not allow the key to be removed from the lock while in the ON position.
Power-On Delays
A delay circuit is required that illuminates warning indicators for a short period of time prior to supplying
power to the lasers.
Beam Attenuators
A permanently attached method of preventing human access to laser radiation other than switches,
power connectors or key control must be employed. On some LMI laser sensors, the beam attenuator is
supplied with the sensor as an integrated mechanical shutter.
Emission Indicator
It is required that the controls that operate the sensors incorporate a visible or audible indicator when
power is applied and the lasers are operating. If the distance between the sensor and controls is more
than 2 meters, or mounting of sensors intervenes with observation of these indicators, then a second

Safety and Maintenance • 10Gocator 2000 Family
power-on indicator should be mounted at some readily-observable position. When mounting the warning
indicators, it is important not to mount them in a location that would require human exposure to the laser
emissions. User must ensure that the emission indicator, if supplied by OEM, is visible when viewed
through protective eyewear.
Warning Signs
Laser warning signs must be located in the vicinity of the sensor such that they will be readily observed.
Examples of laser warning signs are as follows:
PEAK POWER
WAVELENGTH
100mW
600-780nm
CLASS IIIb LASER PRODUCT
INVISIBLE AND/OR VISIBLE LASER RADIATION
AVOID DIRECT EXPOSURE TO BEAM
DANGER
FDA warning sign example
IEC 60825-1:2007
CAUTION
AVOID EXPOSURE
TO THE BEAM
CLASS 3B LASER LIGHT
IEC warning sign example
Systems Sold or Used in the USA
Systems that incorporate laser components or laser products manufactured by LMI Technologies require
certification by the FDA.
Customers are responsible for achieving and maintaining this certification.
Customers are advised to obtain the information booklet Regulations for the Administration and
Enforcement of the Radiation Control for Health and Safety Act of 1968: HHS Publication FDA 88-8035.
This publication, containing the full details of laser safety requirements, can be obtained directly from the
FDA, or downloaded from their web site at http://www.fda.gov/cdrh.

Safety and Maintenance • 11Gocator 2000 Family
Electrical Safety
Sensors should be connected to earth ground
All sensors should be connected to earth ground through their housing. All sensors should be mounted
on an earth grounded frame using electrically conductive hardware to ensure the housing of the sensor
is connected to earth ground. Use a multi-meter to check the continuity between the sensor connector
and earth ground to ensure a proper connection.
Minimize voltage potential between system ground and sensor ground
Care should be taken to minimize the voltage potential between system ground (ground reference for
I/O signals) and sensor ground. This voltage potential can be determined by measuring the voltage
between Analog_out- and system ground. The maximum permissible voltage potential is 12 V but should
be kept below 10 V to avoid damage to the serial and encoder connections. Refer to the Gocator I/O
Connector section (page 175) in this guide for a description of connector pins.
Use a suitable power supply
The +24 to +48 VDC power supply used with Gocator sensors should be an isolated supply with inrush
current protection or be able to handle a high capacitive load.
Use care when handling powered devices
Wires connecting to the sensor should not be handled while the sensor is powered. Doing so may cause
electrical shock to the user or damage to the equipment.
Failure to adhere to the guidelines described in this section may result in electrical shock or
equipment damage.

Safety and Maintenance • 12Gocator 2000 Family
Environment and Lighting
Avoid strong ambient light sources
The CMOS imager used in this product is highly sensitive to ambient light; stray light may have adverse
effects on measurement. Do not operate this device near windows or lighting fixtures that could influence
the measurement. If the unit must be installed in an environment with high ambient light levels, a lighting
shield or similar device may need to be installed to prevent light from affecting measurement.
Avoid installing sensors in hazardous environments
To ensure reliable operation and to prevent damage to Gocator sensors, avoid installing the sensor in
locations;
• that are humid, dusty, or poorly ventilated
• with a high temperature, such as places exposed to direct sunlight
• where there are flammable or corrosive gases
• where the unit may be directly subjected to harsh vibration or impact
• where water, oil, or chemicals may splash onto the unit
• where static electricity is easily generated
Ensure that ambient conditions are within specifications
Gocator sensors are suitable for operation between 0 – 50 °C and 25 – 85% relative humidity (non-
condensing). Measurement error due to temperature is limited to 0.015% of full scale per degree C.
The Master 200 is similarly rated for operation between 0 - 50 °C.
Sensor Maintenance
Keep sensor windows clean
Gocator sensors are high-precision optical instruments. To ensure the highest accuracy is achieved in all
measurements, the windows on the front of the sensor should be kept clean and clear of debris.
Use care when cleaning sensor windows
Use dry, clean air to remove dust or other dirt particles. If dirt remains, clean the windows carefully with a
soft, lint-free cloth and non-streaking glass cleaner or isopropyl alcohol. Ensure that no residue is left on
the windows after cleaning.
Turn off lasers when not in use
LMI Technologies uses semiconductor lasers in 3D measurement sensors. To maximize the lifespan of
the sensor, turn off the laser when not in use.
Avoid excessive modifications to files stored on the sensor
Settings for Gocator sensors are stored in flash memory inside the sensor. Flash memory has an
expected lifetime of 100,000 writes. To maximize lifetime, avoid frequent or unnecessary write
operations.

13Gocator 2000 Family
Getting Started
System Overview
Gocator sensors can be installed and used in a variety of scenarios. Sensors can be connected as
standalone devices, or connected to a Master 200 for synchronized dual sensor (Main and Buddy)
operation, or through a Master 400, 800, 1200, or 2400 for multi-sensor operation.
Standalone System
Standalone systems are typically used when only a single Gocator sensor is required. The sensor can
be connected to a computer’s Ethernet port for setup and can also be connected to devices such as
encoders, photocells, or PLCs.
GOCATOR I/O
CORDSET
ETHERNET
CORDSET
USER PC
(can be disconnected after setup)
GOCATOR
CONNECT POWER AND I/O AS
REQUIRED BY APPLICATION
IN - ENCODER / TRIGGER / SAFETY
OUT - SERIAL / ANALOG / DIGITAL

Getting Started • 14Gocator 2000 Family
Dual Sensor (Buddy) System
In a dual sensor system, two Gocators work together to perform profiling and output the combined
results. The controlling sensor is referred to the main sensor, and the helper is referred to as the Buddy
sensor. Gocator’s software recognizes three installation orientations – Opposite, Wide and Staggered.
The Master 200 can be used to connect 1 or 2 sensors in a Dual Sensor (Buddy) system. Gocator I/O
cordsets are used to connect sensors to the Master 200. The Master 200 provides a single point of
connection for system I/O and power. The Master 200 can be used to ensure that the scan timing is
precisely synchronized across sensors. Sensors and client computers typically communicate via an
Ethernet switch (minimum 100 Mb).
MASTER 200
CAT5E ETHERNET
CABLE
GOCATOR I/O
CORDSET ETHERNET
CORDSET
ETHERNET SWITCH
(NOT SUPPLIED
(BY LMI)
USER PC
MAIN GOCATOR
BUDDY GOCATOR
CONNECT I/O AS REQUIRED BY
APPLICATION
IN - ENCODER / TRIGGER / SAFETY
OUT - SERIAL / ANALOG / DIGITAL

Getting Started • 15Gocator 2000 Family
Multi-Sensor System
Master 400/800/1200/2400 networking hardware can be used to connect 2 or more sensors into a Multi-
sensor system. Gocator Master cordsets are used to connect the sensors to a Master and provides a
single point of connection for power, safety, encoder and digital inputs. A Master 400/800/1200/2400 can
be used to ensure that the scan timing is precisely synchronized across sensors and client computers
typically communicate via an Ethernet switch (minimum 100 Mbaud).
The Master 400/800/1200/2400 are designed to be connected to a control system and unlike the Master
200 does not support digital, serial or analog output.
MASTER 2400
USER PC
GIGABIT ETHERNET SWITCH
CAT5E ETHERNET CABLE
GOCATOR MASTER CORDSET
ETHERNET CORDSET

Getting Started • 16Gocator 2000 Family
Hardware
Sensor
CAMERA
LASER EMITTER
LAN CONNECTOR
I/O CONNECTOR SERIAL NUMBER
POWER, RANGE, LASER
INDICATORS
Item Description
Camera Observes laser light reflected from target surfaces.
Laser Emitter Emits structured light for laser profiling.
I/O Connector Accepts power and input/output signals.
LAN Connector Connects to 100 Mbit/s Ethernet network.
Power Indicator Illuminates when power is applied (blue).
Range Indicator Illuminates when camera detects laser light and is within the target range (green).
Laser Indicator Illuminates when laser safety input is active (amber).
Serial Number Unique sensor serial number.
Sensor Models and Options
The table below summarizes the sensor
models in the Gocator 2000 Family. Refer to the
Specifications section (page 162) or detailed
model specifications.
Each individual sensor can be customized by
specifying its laser class (2M, 3R, 3B) and profile
tools (advanced measurement functions) at the
time of purchase. The Parts and Accessories (page
186) lists the part numbers for each available
combination of model and options.
CLEARANCE DISTANCE
NEAR FOV
FAR FOV MEASUREMENT RANGE
Gocator sensors
2020-YY 2030-YY 2040-YY 2050-YY 2070-YY 2080-YY
Clearance Distance (mm) 40 90 190 300 400 350
Measurement Range (mm) 25 80 210 400 500 800
Field of View (mm) 19 - 26 47 - 85 96 - 194 158 - 365 308 - 687 390 - 1260
*YY= Indicates Laser Class (2M, 3R, or 3B as chosen at time of purchase)

Getting Started • 17Gocator 2000 Family
Master 200
POWER SWITCH
CONNECTION TO SENSOR 1
CONNECTION TO SENSOR 2 LASER SAFETY SWITCH
INPUT/OUTPUT ENCODER
(PORT 1 ONLY)
ENCODER
(PORT 1&2) POWER AND
LASER SAFETY
POWER
(FOR DEMO USE ONLY*)
Item Description
Connection to Sensor 2 Gocator I/O connection for Sensor 2 (Buddy).
Connection to Sensor 1 Gocator I/O connection for Sensor 1 (Main).
Laser Safety Switch Toggles laser safety signal provided to the sensors [O= laser off, I= laser on].
Power Switch Toggles sensor power.
Input/Output Accepts digital input and provides digital output, serial output, and analog output.
Encoder (Port 1 only) Accepts encoder for standalone sensor operation (Main only).
Encoder (Port 1 & 2) Accepts encoder for Buddy sensor operation (Main and Buddy sensors connected).
Power and Laser Safety Accepts power (+24 to +48 V at 10 Watts) and laser safety inputs.
Refer to the Master 200 section (page 180) for pinout details.

Getting Started • 18Gocator 2000 Family
Master 400/800
SENSOR PORTS 5-8
SENSOR PORTS 1-4
LED INDICATORS
MASTER 400 FRONT
MASTER 400 FRONT
MASTER 400/800 REAR
POWER AND SAFETY
ENCODER
INPUT
SENSOR PORTS 1-4
LED INDICATORS
Item Description
Sensor Ports Master connection for Gocators (no specific order required).
Ground Connection Earth ground connection point.
Laser Safety Laser safety connection
Encoder Accepts encoder signal.
Input Accepts digital input.
Refer to the Master 400/800 section (page 182) for pinout details.

Getting Started • 19Gocator 2000 Family
Master 1200/2400
SENSOR PORTS 13-24 (2400 ONLY)
SENSOR PORTS 1-12
LED INDICATORS
GROUND CONNECTION
POWER AND SAFETY
ENCODER
INPUT
SENSOR PORTS 1-12
LED INDICATORS
MASTER 1200 FRONT
MASTER 2400 FRONT
MASTER 1200/2400 REAR
Item Description
Sensor Ports Master connection for Gocators (no specific order required).
Ground Connection Earth ground connection point.
Laser Safety Laser safety connection
Encoder Accepts Encoder Signal.
Input Accepts digital input.
Refer to the Master 1200/2400 section (page 184) for pinout details.

Getting Started • 20Gocator 2000 Family
Cordsets
Gocator sensors use three cordsets. The Ethernet Cordset is used for sensor communication via 100
Mbit Ethernet with a standard RJ45 connector. The Gocator I/O Cordset provides power and laser safety
interlock to sensors, as well as digital I/O connections, an encoder interface,
RS-485 serial connection, and an analog output. The Gocator Master Cordset provides electrical
connection between the sensor and a Master 400/800/1200/2400.
M12 ETHERNET CONNECTOR
4 PIN, D-CODE, MALE
RJ45 8 PIN JACK
CORDSET, GOCATOR, ETHERNET, Xm
M16I/O CONNECTOR
19 PIN, MALE
PIGTAILED LEADS
CORDSET, GOCATOR, POWER/IO, Xm
RJ45 8 PIN JACK
M16I/O CONNECTOR
19 PIN, MALE
CORDSET, GOCATOR, MASTER, Xm
Refer to the Gocator I/O Connector section (page 175) pinout details. Refer to Parts and Accessories
(page 186) for cordset lengths and part numbers.