User manual PosCon english
Contents
1. Baumer electric Leading in precision sensing User Manual Line sensor PosCon ZADM 22kK und ZADM 22H Seite Page 37 Contents Introduction Getting started guide The PosCon system The keypad Measurement types Installation Application information Programming the measurement types Teaching the switching output Outputs Inputs Serial interface RS485 optional Service instruction Technical data Accessories ON Oa BWOHND m O A ON a oO Safety instruction Safety concept information and limiting parameters as published in the sales documentation applies at all times Seite Page 38 1 introduction The PosCon is a competitively priced solution for many applications such as the measurement of fabric width monitoring the position of threads or wires or positioning web edges for example The development aim of the PosCon designers was to help end users avoid the complexities found in the application of many currently available sensing methods So the engineers main tained a commitment to keeping operation and mounting simple In most cases the measurement of web edge object width or thickness is carried out by sensing a particular line established as a point on the moving product Until now line cameras have been the method of choice for such measurements A line camera in simple terms is a video camera that has a single line of photo elements instead of a matrix The PosC2. Page 68 13 Technical data ZADM 022 x871 ZADM 022 x151_ 350 mm 400 875 mm Smallest recognizable object 0 3mm 1 2mm 4mm 8 18 mm 0 03 mm 0 15 mm 0 35 mm 0 5 1 mm Infrared LED 880 nm Technical data ZADM 022 x300 max 1 Measuring frequency gt 130 sec gt 120 sec with polarization filter Analog output 4 20 MA 420M S O O Switching output NPN or PNP 15 28 V lt 150 mA Output short circuit protec ye tion ye s Voltage supply reverse s polarity protection 0 55 C Front optics Temperature range housing Zinc die cast Protection class IP 67 Seite Page 69 Dimensions ap ap Fe receiver axis Connection diagram O Analogue output Out O Alarm output or Out 2 MERRIA ORx Tx BA ORx Tx OGND Enable O ADS only at RS 485 Seite Page 70 14 Accessories reflector and reflector tape Reflector Reflector tape Reflector tape Active area mm Size mm on reel For measuring range 30mm _ 131245 5x40 137624 136729 m For measuring range150 mm 131246 20x 175 137625 20 x 175 136730 m For measuring range 350 mm 131247 35 x 395 137626 35 x 395 136731 m Reflector tape width 630 mm 144559 m Connector and mounting bracket connector 8 Pol M12 x 1 ESG 34FP0200B Mounting bracket 126220 Seite Page 71
3. Page 48 6 2 Measuring distance Measuring range Size of reflector The nominal measuring range is specified in the datasheet for the particular PosCon model If the distance between the object and the sensor dif fers from the nominal measuring distance the meas T uring range will be changed Ideal measuring distance 10 of the nominal measuring range Max Distance sensor reflector 50 of the nomi nal measuring distance The measuring range can be calculated as follows nominal measuring range x measuring distance measuring range specified measuring distance 1 gt reflector Measuring range Seite Page 49 If it is not possible to place the object in the nominal measuring range please be aware that with deviations of less than 10 of the nominal measuring distance the sensor works at its best The correct size of the reflective tape can be calculated as follows 1 2 x nominal measuring range x distance to reflector length nominal measuring distance recommended width measuring distance 50 mm gt 5 mm measuring distance 150 mm gt 20 mm measuring distance 350 mm gt 35 mm The angle of the reflector against the sensor axes must be within 20 Seite Page 50 7 Application information 7 1 Extended objects The sensor recognizes only the outermost edges of an object When objects extend toward the sensor this can lead to different values
4. 11 2 Command mode In a single sensor configuration this mode allows a transmission of the measured values with maxi mum speed and no protocol overhead The measuring type cannot be changed in this mode It must be set before using the button There are four commands for master sensor communication command Function Response Measured data FF Request for measured value 2 Byte binary 1 Hi Byte 2 Low Byte 08 Switch to protocol mode None 0A Continuous data 2 Byte binary Hi Byte data Bit 0 4 Bit 8 1 Low Byte data Bit 0 4 Bit 8 0 Sensor sends continuously data until the sen sor receive FF or 08 99 x Set delay for sensor answer Factory setting is 0 2ms x is one Byte binary It sets the delay in incre ments of 0 1ms The value of x may vary from 0 0 1ms to 255 25 6ms The sensor must have been in command mode for at least 10ms No further command for the next 20ms Seite Page 61 Seite Page 62 11 3 Protocol mode Time delay of sensor This mode allows multi sensor configurations with one master T1 T3 T5 can be set from 0 1 ms to 25 6 ms Protocol sequence delay of master In this operating mode the sensor is always the slave Every command starts with an ENQ followed by the sensor s T2 T4 must be lt 150 ms address The sensors response to ENQ is ACK Next the master sends data between STX and ETX The data con tains the actual command and if required parameters If the command sent
5. by the master initiates an action the sensor responds with ENQ followed by its own address The master then responds with an ACK and the sensor starts F transmitting the answer between STX and ETX Data coding example Master sends a command which initiates a response from the sensor Master sends delay Sensor with address 2 sends ENO gt pe T1 Time between ENQ from master and ACK from sensor lh SEES ee ae oe ee en ge ACK i T2 Time between ACK and data transmission to the I sensor STX lt data gt ETX 3 Time between data transmission from master and ENQ from sensor ENQ 2 T4 Time between ENQ from sensor and ACK from master ACK T5 Time between ACK from master and data transmis sion from sensor PO ST X lt at gt ETX Seite Page 63 The data values are coded in ASCII hexadecimal numbers Each byte represents a hexadecimal digit Example To transmit the value 755 the number is transformed to a hexadecimal number 2F3 the sign indicates a hexadecimal number Now each digit is transmitted with its ASCll Code 32 for 2 46 for F 33 for 3 Valid characters letter A Z capital letters only numbers 0 9 special character lt ENQ ASCII character 5 ready to send enquiry ACK ASCII character 6 ready to receive acknowledge STX ASCII character 2 start of text ETX ASCII character 3 end of text Seite Page 64 Commands in protocol m
6. outer most left edge inside the measuring range left i left E left right No edge inside the measuring range gt analog output 4 mA Seite Page 45 5 2 Edge position right edge The sensor is measuring the outermost right edge inside the measuring range left A right left right left j t No edge inside the measuring range gt analog output 4 mA 5 3 Center position The center position between the two outermost edges inside the measuring range is measured No or one edge inside the measuring range gt analog output 4mA Seite Page 46 5 4 Width measurement Distance between edges The sensor measures the distance between the outermost edges inside the measuring range left right left right le No or one edge inside the measuring range gt analog output 4mA 5 5 Width measurement Sum of all objects sizes The sensor measures the sum of all objects sizes inside the measuring range left right left ight lt gt lt gt The whole measuring range is covered gt analog output 20 mA No object inside the measuring range gt analog output 4 mA This mode is used in initial sensor reflector orientation gt Seite Page 47 6 Installation 6 1 Alignment Set the measurement type to Width measurement Sum of all object sizes If the reflector is well aligned the output value will be 4mA v Analog output l 4mA Analog output Analog output l gt 4mA l gt 4mA v X X Seite
7. ye O00 nn O08 ann C0 OB js es LOR Edge position right O IB oe LOR Centre position Width measurement Sum of all objects Width measurement Distance between edges gt width between the outermost edges is displayed Edge position left gt the first edge from left is displayed gt the first edge from right is displayed gt centre position between the out ermost edges is displayed gt sum of the width of all objects is displayed Seite Page 41 2 3 Teaching the thresholds set points This allows the user to teach the sensor a min max window of acceptance for targets Sensors with one digital output a min 2 sec gt TEACH LED is blinking TEACH gt TEACH LED blinks fast for a gt TEACH blinks fast for a short short time time gt place an object which repre sents the first tolerance value gt place an object which repre gt the two thresholds are taught sents the second tolerance va Sensors with two digital outputs OU to min 2 sec gt S1 LED is blinking gt S1 LED blinks for a short time gt S2 LED is blinking for a short S2 is blinking time gt place the object for the first threshold gt place the object for the second gt the two thresholds are taught threshold Seite Page 42 3 The PosCon system 1 edge left Start of measuring range 4 mA output 1 edge right Re
8. ent type of measurement Note The type of measurement and the tolerance limits for the switch ing output remain stored even after power down Two buttons help to program the sensor easily The MOD and PROG buttons are for programming the type of measurement The SET button is for setting the threshold set points of the switching out put Press the PROG button for more than 2 seconds to enter the programming mode The measurement type indicator LED is now blinking To return to run mode after setting the right type of measurement press the PROG button again for more than 2 seconds Bf min 2 sec Seite Page 54 Press the MOD button to switch between the measuring types DOL Sam at Edge position left edge Width measurement Sum of all objects l 1 i of e DEL PROG Width measurement Distance between edges Edge position right edge Center position Seite Page 55 9 Teaching the switching output It is possible to set two threshold values inside the analog value of 4 20 mA Depending upon the values programmed into the switching output and the status of the actual measured value the switching output will either be High or Low For teaching the threshold value it is necessary to simulate the tolerance position of the object or the tolerance size of the object One switching output procedure 0 SET J min 2 sec 0 gT O gT TEACH TEACH TEACH gt TEACH LED
9. flective tape End of measuring range 20 mA output The sensor consists of infrared emitters a receiver the electronic components and the interface In addition a reflective tape is necessary For orientation the system has a right R and a left L side and is indicated on the sensor housing This corresponds to the analog output of the signal left side equals 4mA while right side equals 20mA Every change from bright to dark or dark to bright inside the measuring range is an edge for the sensor Corresponding to the chosen measuring mode the sensor evaluates these edges and displays it on the analogue output Seite Page 43 4 The keypad Select button for type Indicator LEDs for meas of measurement urement types Start button for pro gramming the type of measurement Indicator LED for teach mode also indicates the status of the switching output Button for teaching the thresholds Seite Page 44 5 Type of measurement General information e All dark gt bright or bright gt dark changes inside the measuring range indicates an edge An uncovered part of the reflective tape inside the measuring range indicates a bright section A covered part of the reflective tape inside the measuring range indicates a dark section No edge inside the measuring range means no object or an object that covers the whole measur ing range 5 1 Edge position left edge The sensor is measuring the
10. for different posi tions within the measuring range Position 1 one front and one rear edge will be measured Position 2 the front edges will be measured The measured size of object in Position 1 is bigger than the object in Position 2 Positi on 2 Seite Page 51 7 2 Reflective tape covered by plexiglass If the reflective tape is covered by glass or plexiglass the reflector must be tilted because a reflection from the reflector may disturb the meas urement The angle is approximately 5 Attention The reflector must be tilted as shown in the drawing 7 3 Glossy objects If very glossy objects must be meas ured a reflection from the object may disturb the measurement In this case it helps to tilt the object The reflection will thus be reflected away from the sensor measuring range 30 mm approximately 7 Attention The object must be tilted in the axis shown in the drawing measuring range gt 150 mm approximately 3 Seite Page 52 7 4 Transparent objects polarization filter types only The sensor with the built in polarization filter detects and measures clear transparent objects In this case it is necessary to tilt the object The angle between the sensor and the object must be less then 25 Reflector Transparent object 25 wy Seite Page 53 8 Programming the measurement type The PosCon starts in Run mode The LEDs indicate the curr
11. he current is between 4 20 mA 10 2 Switching output Depending on the threshold values and the measuring value the switching output or the two switching output depending on sensor type is High or Low Logic of the switching output one switching output If threshold 1 lt threshold 2 the switching output is ON if the measured value is between threshold 1 and threshold 2 otherwise OFF If threshold 1 gt threshold 2 the switching output is OFF if the measured value is between threshold 1 and threshold 2 otherwise ON Logic of the switching output two switching outputs If measured value gt threshold 1 the switching output S1 is ON otherwise OFF If measured value gt threshold 2 the switching output S2 is ON otherwise OFF Seite Page 58 10 3 Alarm output The sensor will compensate for soiled optics to a certain limit If this limit is reached the alarm output will be activated grey wire pin 5 10 4 Switching input Enable The switching input red wire pin 8 can gate the switching output Sensor with one switching output Switching input connected to GND or not connected The switching output is active Switching input connected to Vs The switching output is OFF Sensor with two switching outputs Switching input connected to GND or not connected The switching outputs are active Switching input connected to Vs The switching outputs are memorised Seite Page 59 11 Serial in
12. is blinking gt TEACH LED blinks fast for a short time gt TEACH LED blinks fast for a short time gt place an object which repre sents the first tolerance value gt place an object which represents the second tolerance value gt the two thresholds are taught Seite Page 56 Two switching outputs procedure OO Ca O00 jas gt S1 LED blinks fast for a s hort gt go LED blinks fast for a short time S2 is blinking time OO to min 2 sec gt S1 LED is blinking gt place an object which represent the first tolerance value gt place an object which represent gt the two thresholds are taught the second tolerance value Logic of the switching output one switching output If threshold 1 lt threshold 2 the switching output is ON if the measured value is between threshold 1 and threshold 2 otherwise OFF If threshold 1 gt threshold 2 the switching output is OFF if the measured value is between thresh old 1 and threshold 2 otherwise ON Logic of the switching output two switching outputs If measured value gt threshold 1 the switching output S1 is ON otherwise OFF If measured value gt threshold 2 the switching output S2 is ON otherwise OFF Seite Page 57 10 Inputs outputs 10 1 Analog output The zero point of the measuring range is on the left side written on sensor Depending on position of the object and the type of measurement t
13. ode Function Data Assign new ad D x dress x 0 9 or F for ad dress FF Example STX D3 ETX Response ENQ new address ACK will be awaited Assign address 3 to the sensor Set type of meas B x STX B3 ETX Type of measure urement 1 left edge ment is centre 2 right edge position 3 centre position 4 width distance edges 5 width sum of objects 6 number of edges F Xxx yyy xxx and yyy are 3 digit hexadecimal numbers Between 0 and 1023 FOC620A ETX Set threshold 1 to 0C6 198 Set threshold 2 to 20A 522 Data request Set threshold level Data request 4 bytes meas ured value Status request STX H ETX Status request 26 Bytes status table Keyboard control STX G ETX Switch keyboard off Wee EE S ee on keyboard off Switch to com C mand mode lt parameter Seite Page 65 Status request meaning of the bytes Byte Nr 1 2 e 3 4 Can not be changed by the user 7 8 Hi Byte of threshold level 1 9 10 LowByteofttreshodieet 2 m HByeottivestoidied 2 B LowBytecftivestodiet2 Sooo 15 16 Duration of posure As long as this value is below max exposure tine the sensor is not soiled 17 18 Type of measurement This two bytes represent the actual type of nreasurement Bit O Sensor stays in programming node Bit 1 Sensor stays in SET Mode Bit 2 number
14. of edges Bit 3 left edge Bit 4 right edge Bit 5 center position Bit 6 width distance edges Bit 7 width sumof objects Exanple Sensor sends ASCII Code 30 38 heedecimal number 08 or binary 000071000 gt left edge 19 20 21 22 23 24 Max exposure value Factory set If the value duration of exposure reach this limit the alanmoutput is set 25 26 Intemal paranreter Factory use only Seite Page 66 11 4 Examples Sensor 5 set type of measurement to center position ENQ 5 05 35 06 ACK 02 42 33 03 DO Sensor 2 data request actual value 416 or 01A0 Master sends Transmitted bytes in hexadecimal n A ETX 02 41 03 05 32 aN 2 ACK 506 E rr Sensor sent o ooo sends Sensor 7 set thresholds to 498 and 517 logic of the switching output the switching output is ON if the measured value is between threshold 1 and threshold 2 otherwise OFF Master sends Transmitted bytes in hexadecimal Sensor sends ENQ 7 05 37 We ee I O0Cs i es ae rea e e e a 46 31 46 32 32 30 35 03 o Seite Page 67 11 5 ASCIl Code Table examples ENQ 05 A 41 12 Service instruction Check the measuring system for cleanliness at regular intervals Especially keep the front cover optics and the reflector clean Every particle water drops heavy dust on the reflector could be recognized as an object Seite
15. on also uses the principle of inline measurement However instead of complex camera elements the PosCon utilizes a line of simple photodiodes This combination of minimal compo nents and the commitment to trouble free set up and use has helped Baumer electric develop a product that performs like an expensive vision system but retains the cost effectiveness and sim plicity of a sensor Seite Page 39 2 Getting started guide After powering on the PosCon starts in RUN mode 2 1 Mounting and alignment Mount the sensor at the proper distance to the target according to the datasheet If the target is presented at a different distance the range and output changes proportionally For optimum results the object should be kept within 10 of specified measuring range To align the sensor set programming mode to Width measurement Sum of all objects see chart 2 2 The analog output will be 4mA when the sensor is properly aligned with the reflective tape g N Recommended length of reflective tape 1 2 x Measuring range x distance tape Length Measuring distance Recommended width of reflective tape Measuring range 50 mm gt 5 mm Measuring range 150 mm gt 20 mm analog output analog output analog output cod aoe ae Measuring range 350mm gt 35mm l 4mA l gt 4mA l gt 4mA v x x Seite Page 40 2 2 Programming the type of measurement Press the MOD button to switch between the measuring types B00
16. terface RS 485 optional 11 1 General Certain models of the PosCon contain a serial port RS 485 Via this port all data can be acquired which is available on the analog output All types of measurements can be set the buttons can be disabled and enabled and more functions are available There are two modes in which the RS 485 can be run Command mode The sensor is a single sensor connected to the serial port No address is necessary No time consuming protocol overhead Protocol mode The RS 485 can be run as a bus with one master and several sensors as slaves Each sensor has his own address The sensor comes with a factory set address of FF The address can only be changed in protocol mode The sensor will start always in command mode whether it has the address FF or his own address Note The address remains stored even after power down Note Keypad buttons cannot be pressed during the transmission of data Note When sending 0A8 or FF to stop continuous data mode 0A both the digital and analog outputs will give a brief on off digital output and a current spike analog out put When using continuous data mode it is recommended that you ignore both the digital and analog output for a 1 second period after sending 08 FF Seite Page 60 Specification Standard 19200 Baud Start Stop Bits 1 start bit 1 stop bit Data length 8 Bits Parit none Operating mode Half duplex
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