Baumer PosCon3D Operating Instructions Manual

Contents

1

1.1

1.2

1.3

2

2.1

2.2

2.3

2.4

2.5

3

3.1

3.2

4

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

General information ...................................................................................................................... 4

Concerning the contents of this document ..................................................................................... 4

Intended use ................................................................................................................................... 4

Safety notes .................................................................................................................................... 4

Commissioning in 4 steps ........................................................................................................... 5

Connection ...................................................................................................................................... 5

Installation ....................................................................................................................................... 6

Measuring mode ............................................................................................................................. 7

Measurement ................................................................................................................................ 10

Optional settings ........................................................................................................................... 10

Connection .................................................................................................................................. 11

Connection cable .......................................................................................................................... 11

Pin assignment and connection diagram ...................................................................................... 12

Installation ................................................................................................................................... 13

Mounting ....................................................................................................................................... 13

Sensor reference levels ................................................................................................................ 13

The reference surface ................................................................................................................... 14

Sensor alignment .......................................................................................................................... 15

Standard installation ..................................................................................................................... 16

Angled installation ......................................................................................................................... 18

Blind region ................................................................................................................................... 19

Practical zero point search ........................................................................................................... 20

Installation accessories ................................................................................................................. 20

5

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.12

6

6.1

6.2

6.3

6.4

6.5

6.6

6.7

7

7.1

Configuration via touch panel ................................................................................................... 22

Overview of control elements ....................................................................................................... 22

Function tree ................................................................................................................................. 25

LIVE MONITOR ............................................................................................................................ 27

MEAS TYPE ................................................................................................................................. 28

EDGE HEIGHT / OBJECT HEIGHT / GAP DEPTH ..................................................................... 32

OBJECT ........................................................................................................................................ 32

PRECISION .................................................................................................................................. 32

FLEX MOUNT ............................................................................................................................... 34

FIELD OF VIEW ........................................................................................................................... 38

DIGITAL OUT ................................................................................................................................ 43

SYSTEM ....................................................................................................................................... 44

SETTINGS .................................................................................................................................... 45

Function and definition .............................................................................................................. 47

Datasheet...................................................................................................................................... 47

Dimensions ................................................................................................................................... 49

Functional principle ....................................................................................................................... 50

Object to be measured ................................................................................................................. 52

Interfaces and outputs .................................................................................................................. 54

Touch panel................................................................................................................................... 58

Memory ......................................................................................................................................... 58

Safety instructions and maintenance ....................................................................................... 59

General safety instructions ........................................................................................................... 59

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7.2

7.3

7.4

7.5

8

8.1

8.2

9

Laser class .................................................................................................................................... 59

Influence of ambient light .............................................................................................................. 59

Front (optics) ................................................................................................................................. 59

Cleaning the sensors .................................................................................................................... 60

Error correction and tips ............................................................................................................ 60

Effects of deviations in the inclination angle ................................................................................. 60

Error correction ............................................................................................................................. 61

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.

Read these operating instructions carefully and follow the safety instructions!

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.

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2 Commissioning in 4 steps

Key functions

1

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.

1

2

3
4

5

6

Function Edge Function Width Function Gap

2.1 Connection

Optional: Measuring field limitation

Optional: Switching output

Connection

Installation

Let's get started

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.

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

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2.2 Installation

Standard installation

Angled installation

2

0 mm

right left

150 mm

<100 mm

0 mm

right

0 mm

150 mm

+/-30°

<100 mm

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.

Measuring

field

-62.5 mm
@250 mm

+62.5 mm
@250 mm

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.

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..

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.

Measuring

field

-73.0 mm
@250 mm

+54.6 mm
@250 mm

Reference surface

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.

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2.3 Measuring mode

EDGE: Edge (basic setting)

EDGE HEIGHT

3a

Min. edge height

Object

Reference

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

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)

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WIDTH: Width measurement

OBJECT HEIGHT

3b

Min. object height

Object

Reference

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.

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)

WIDTH CENTER WIDTH

Distance between sensor
and reference surface too
long
Installation angle too
large
Reference surface too
uneven
Reference surface too
small (<50 mm)

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GAP: Gap

measurement

GAP DEPTH

3c

Min. gap depth

Object

Reference

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.

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)

GAP CENTER GAP

Distance between sensor
and reference surface
Installation angle too large

Reference surface too
uneven
Reference surface too
small (<50 mm)

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2.4 Measurement

Measuring field limitation

Switching output

Let's get started

4

5a

5b

LIMIT LEFT

LIMIT RIGHT

OFFSET

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.

2.5 Optional settings

(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

(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.

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Left Right

Point Window

Left Right

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3 Connection

contact

between the eye and beam should be avoided.

ATTENTION!

Incorrect supply voltage will destroy the device!

ATTENTION!

Connection, installation and commissioning may only be performed by qualified
personnel.

ATTENTION!

The IP protection class is valid only if all connections are connected as
described in the technical documentation.

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

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.

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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
Pin 3
Pin 4
Pin 5 GY = gray alarm Alarm-out, push-pull
Pin 6
Pin 7
Pin 8

BN = brown + Vs Voltage supply (+15…+28 VDC)
GN = green analog Output analog (4…20 mA or 0…10V)
YE = yellow out Switch-out, push-pull

PK = pink Rx/Tx+ RS485 receive/transmit+ (A)
BU = blue 0V Ground GND
RD = red sync in Input synchronization

NOTE

It is recommended to connect unused inputs to GND (0V).

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4 Installation

ATTENTION!

Connection, installation and commissioning may only be performed by qualified
personnel. Protect optical surfaces from moisture and dirt.

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 R2

13 mm

Left Right

Laser
beam

Level R3

Level R1

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4.3 The reference surface

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.

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

Angle deviations can affect measuring accuracy (see Section Alignment errors).

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.

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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

axis

The important terms "Left" and "Right" are to be regarded respectively from the viewpoint of the connector.

The sensor measures objects and edges
at a distance of 150 … 250 mm (z axis)

Left

Right

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.

Blind region

-37.5 mm

Reference

-62.5 mm

5.75 mA / 1.87 V

Measuring

Measuring
field

Z

X

0 mm

12 mA / 5 V

+37.5 mm

100 mm

+62.5 mm

18.25 mA / 8.12 V

Note

On the analog output:

250 mm

0 mm

For further explanations, see
Section "Function and definition“ ­> "Interfaces and outputs" ->
"Analog signal output".

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4.6 Angled installation

0 mm

250 mm

K

M

0 mm

K

field

K

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.

+30…0°

0…-30°

M

Reference surface

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.

Example with -30° inclination

Example with -20° inclination angle

Blind region

Measuring

0 mm

field

M

-73.0 mm
Reference point Reference point

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0 mm

-68.8 mm

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250 mm

Blind region

Measuring

+57.3 mm

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Frauenfeld, Switzerland

0 mm

0 mm

250 mm

K

M

K

field

Example with -15° inclination

Example with -10° inclination

Blind region

Measuring

250 mm

Blind region

Measuring

field

0 mm

-67.0 mm
Reference point

M

+58.6 mm

0 mm

-65.4 mm
Reference point

+59.9 mm

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.

Blind region

250 mm

100 mm

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4.8 Practical zero point search

NOTE

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.

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.

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

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