USER MANUAL

FOR DENEX VERSIONS: 2010

DENEX® Edge Detector II

FLDM 180C1103/S42
 READ THIS FIRST
Before installing, operating, opening, or applying the DENEX Edge Detector II sensor, read
and understand the contents of this manual.

Always observe the following warnings and cautions when operating or working on the
equipment.

CAUTION
Use of controls or adjustments or performance procedures other
than those specified herein may result in hazardous radiation exposure.
Do not stare into laser beam.
The DENEX Edge Detector II must be applied, installed, adjusted, and maintained only by
qualified personnel who are familiar with the operation of the unit and its associated
components.

User Manual DENEX Edge Detector II 2/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
CONTENTS
1 RECEIVING AND HANDLING _________________________________________ 4
2 BASIC FUNCTION ___________________________________________________ 4
3 INSTALLATION ______________________________________________________ 5
3.1 General Precautions ____________________________________________________ 5
3.2 Mechanical Installation _________________________________________________ 5
3.3 Electrical installation ___________________________________________________ 6
3.3.1 Power Connection _______________________________________________ 6
3.3.2 Output Signal ___________________________________________________ 6
4 SOFTWARE FUNCTIONS _____________________________________________ 8
4.1 Blocking Function ______________________________________________________ 8
4.2 DIP-Switch Settings ____________________________________________________ 9
5 LED INDICATORS __________________________________________________ 10
5.1 The POWER-LED ______________________________________________________ 10
5.2 The LASER OFF-LED __________________________________________________ 10
5.3 The OUTPUT-LED _____________________________________________________ 10
6 TECHNICAL SPECIFICATIONS ______________________________________ 11
7 ACCESSORIES _____________________________________________________ 12
8 LASER SAFETY ____________________________________________________ 12
9 TROUBLESHOOTING _______________________________________________ 13
9.1 Maintenance at Regular Intervals _______________________________________ 14
10 RETURNING EQUIPMENT _________________________________________ 15
11 WARRANTY ______________________________________________________ 15
12 APPENDIX _______________________________________________________ 16
13 Supplements _____________________________________________________ 17

User Manual DENEX Edge Detector II 3/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
1 RECEIVING AND HANDLING
Upon delivery of the equipment, thoroughly inspect the shipping containers and contents
for indications of damage incurred in transit. If any concealed loss or damage is
discovered, notify the forward agent.
A complete DENEX Edge Detector II shipping box should contain:
1 DENEX Edge Detector II
1 Female Connector, Amphenol Tuchel T3476 001
1 Installation Manual

2 BASIC FUNCTION
The DENEX Edge Detector II is a non-contact sensor, which counts all kinds of printed
products on an overlapped stream. It senses the leading edge and generates one output
pulse for every product. Product thickness from a single folded sheet up to a maximum
stream thickness of 70 mm can be sensed without adjustments.

The laser diode that is used produces a visible and very intensive and focused light beam
that is projected onto the stream. The reflected light from the spot is collected by two light
sensitive detectors P and R and is analyzed by a microprocessor. The difference in
reflected light that occurs, when the light spot is temporarily hidden behind the passing
product edge provides the basic data for the sensor to determine a count output pulse.

Figure 2.1 The principle of operation

The microprocessor controlled DENEX Edge Detector II can be adapted to different

operating modes by changing DIP-switches, which can be reached from outside, via the
lid.

User Manual DENEX Edge Detector II 4/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
3 INSTALLATION
3.1 General Precautions
The DENEX Edge Detector II should be installed in an environment where:
1. The equipment ambient temperature does not exceed 40º C.
2. The equipment atmosphere is free from highly flammable or combustible vapors,
corrosive chemical flumes, oil vapor, steam, excessive moisture and particles.

Avoid mounting the unit in places with strong vibrations since they can produce miscounts,
especially when thin products are counted. Make sure that the mounting bracket and
means used are rigid to withstand vibrations.

3.2 Mechanical Installation

The sensor should normally be mounted on a flat conveyor. It is possible to mount the
sensor on a bent part of the conveyor according to figures below. Do not mount according
to Figure 3.2.1 (right) since it will deteriorate the function of the unit.

YES NO

Figure 3.2.1 Mounting on a non-flat conveyor.

The sensor should be mounted parallel to, and at a distance of 100 mm from the conveyor.
When the laser does not hit a product, it should hit a light, matte surface at 100 - 150 mm
below the sensor. The reference surface must be smooth. If the surface is wrinkled or
coarse, vibrations can cause error pulses. Also, make sure that dust and paper pieces do
not stay on the surface, since they could also create output pulses. Make sure that the
laser beam is properly stopped by this surface, so that it is impossible for a user to be
exposed to the laser beam.

User Manual DENEX Edge Detector II 5/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
 DENEX
DEN EX
keeps an eye on your
pr oducti on

DENEX SYSTEM S
TEC HN O LO G Y
Laser CopySensor™
Edge Detector II
DENEX Systems Technology AB Solkraftsvägen 3 1, S-135 70 Stockholm, Sweden
Tel : + 46 (8) 7 12 00 20 Fax: + 46 (8) 712 59 4 5 E- mail: techsupport.dst@denex.se

Figure 3.2.2 Mechanical mounting with reference surface.

3.3 Electrical installation

The interface to the copy sensor is a 7-pin connector with the following pin-out:
Matching connector: Amphenol Tuchel T3476 001, delivered with the sensor.

Pin 1 : +24VDC in
Pin 2 : + Output (collector)
Pin 3 : Not connected
Pin 4 : Not connected
Pin 5 : - Output (emitter)
Pin 6 : 0V
Pin 7 : No function

3.3.1 Power Connection

Proper wiring techniques are essential for successful system installation. To reduce the
effects of electrical noise interference and static discharge, the procedures outlined in this
section must be strictly followed.
The sensor shall be connected to 24 VDC regulated power.
It must be free from transients!
Never connect or disconnect any cables when the power is on!
The normal current consumption is 150 mA.

3.3.2 Output Signal

The output is a normally open, opto-isolated transistor. Every output pulse is signaled as a
closing of the output for a certain time; see also “DIP-Switch Settings”
The specification for the output opto-coupler is as follows:
Max load current: 100 mA
Max voltage: 35VDC

User Manual DENEX Edge Detector II 6/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
3.3.2.1 Output Signal – Connections
The output can be used for both "current source" and "current sink" depending on what is
required by the equipment. In current source mode, the sensor output will give a positive
pulse to the stacker/totalizer when active. In current sink mode, the sensor output will give
a negative pulse. Figure below shows a common 24 VDC as power supply and feeding the
pulse. It is possible to have different power supplies. In that case, the 24V power is
connected to pins 1 and 6, and the totalizer can be connected to pins 2 and 5.

Figure 3.3.2.1.1 Electrical connection, common 24V-supply. Current source (PNP).

Figure 3.3.2.1.2 Electrical connection, common 24V-supply. Current sink (NPN).

Copy Sensor

Figure 3.3.2.1.3 Electrical connection, separate supply for power and pulse.

User Manual DENEX Edge Detector II 7/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
4 SOFTWARE FUNCTIONS
The benefit with the microprocessor-based copy sensor is that the sensor learns what the
products and the stream look like and make decisions according to this.

Application Setting
Things like output pulse width, Blocking Function and other parameters are set a little
different for each application in order to reach the highest possible accuracy.
There are DIP-switches that tell the sensor which application it should be set for.
It is very important to set the right application!

4.1 Blocking Function

This function will eliminate false counts due to double edges or a cut-edge-first delivery.
The sensor will count edges coming within the blocking zone as one product. In
productions using stitches, extra pulses due to the stitch are blocked out by this function.
The blocking zone is a dynamic value that constantly adapts to the average distance
between copies. It will be 15%, 30 % or 46% of the average lap, depending on application.
The average distance between copies is 100%, see figure 4.1.

Figure 4.1 The principle of the blocking function. The blocking zone is marked with grey.
15% is dark grey, 30% both grey sections.
The 46% blocking zone is marked with arrows.

For irregular product streams where the lap distance between each copy varies much, the
above described blocking function, can block out copies. This gives the result that there
are too many copies in each bundle. For such cases a special mode is available in the
software, Mode 11.
Our general recommendation is to try to adjust the machinery and get correct stream
conditions, so the lap distance between each copy becomes equal.

User Manual DENEX Edge Detector II 8/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
4.2 DIP-Switch Settings
An 8-pole DIP-switch can be reached via the lid on top of the sensor. Unscrewing the
screw opens the lid.
The software functions can be controlled via the DIP switches.

DIP-Switch positions
= OFF
= ON

DIP-switches 1-4 are reserved for factory.

DIP-switches 5-8 are for selecting operation mode
All in OFF-position is the default setting.

DIP-Switches
5 6 7 8
Mode 0 = Commercial products: For timing applications, Blocking 15%, Output 5 ms
Default
Mode 1 Counting application: Blocking time 30%, Output 5 ms
Mode 2 Timing application: Blocking time 15%, Output: 20 ms
Mode 3 Counting mode: Blocking time 15%,Otput: 20 ms
Mode 4 Newspapers, Blocking time 30%, Output: 20 ms
Mode 5 Edge detecting: Blocking time 15%, Output: 5 ms

Mode 6 Edge detecting: Blocking time 15%, Output: 20 ms

Mode 7 Cut edge first mode: Blocking time 46 %, Output 20 ms
Mode 8 Counting mode: Fixed blocking time = 7 ms, Output 5 ms.
Mode 9 Commercial: No Blocking, Output 5 ms
Mode 10 reserved
Mode 11 reserved

Laser power save mode is activated in all Counting/newspaper modes.

This means the laser power will be reduced to 50% after a 60 seconds gap.

User Manual DENEX Edge Detector II 9/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
5 LED INDICATORS
There are four LED’s that are placed close to the connector.

Power (Green)
Laser off (Red)
Output (Orange)
Not used (Y ellow)

5.1 The POWER-LED

The green POWER-LED indicates that the sensor has power and should be operating.
For laser safety reasons never mount or adjust the sensor when Power-LED is on!

5.2 The LASER OFF-LED

The LASER OFF-LED is an indication that the laser is off. The laser will be shut off for the
following reasons:
• The laser power has exceeded the allowed limits (electronic problem inside sensor)
• The laser power has reached lower than acceptable level (laser is worn out, or
electronic problem)

If the laser levels are outside of the allowed limits, the sensor must be sent for repair.

5.3 The OUTPUT-LED

The OUTPUT-LED is active when the output stage is active (set). The LED will flash for
every output pulse.

User Manual DENEX Edge Detector II 10/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
6 TECHNICAL SPECIFICATIONS
Maximum < 600.000 copies/hour
Count Rate
Maximum 1 m/s (200 ft/min) for thinnest product, up
Product Speed to 2 m/s otherwise
Maximum 70 mm (2.76”) standard range
Stream Thickness
Minimum 0,25 mm (0.01”) standard range
Product Thickness
Distance 100 mm (3.94”) standard range
From Conveyor
Minimum Spacing 1-5 mm (0.039-0.20”) dep. on thickness,
Between Copies speed and pulse width
Stream Folded edge first. Cut edge first possible,
Conditions but not recommended.
Operating RISC microprocessor
System
Pulse 5 ms (preset) and 20ms
Width
Output Opto-isolated transistor
Signal 5 to 30V max. 150 mA
Matching Female Amphenol-Tuchel C91A
Connector T 3476 001
Laser System Visible, switched laser diode,
650 nm, with laser safety monitor
Laser Safety Class II
Class
Estimated Lifetime > 50,000 h @ 20ºC
of Laser
Weight 800 g, 1.75 lbs.
Size 175 x 96 x 31mm
6.89 x 3.78 x 1.22”
Power 24 VDC,
150 mA typical
Temp. Range +10 to 40ºC
50 to 104ºF

DENEX Edge Detector II is a Class II Laser Product.

User Manual DENEX Edge Detector II 11/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
7 ACCESSORIES
There are a number of accessories available from Baumer that can save you time and
ensure a good operation of the sensor. Kits for replacing mechanical or older sensors are
available. See web site www.baumer.com or www.denex.com for more updated
information.

8 LASER SAFETY
A Class II-laser product as the DENEX Edge Detector II is said to be safe if a person does
not stare into the beam. If a person accidentally would look into the laser, the strong light
would cause the eyes to shut automatically before any damage to the eyes could occur. If
the following precautions are followed, nothing can happen.

CAUTION
• Do not stare into the laser beam or a reflection of the beam from a mirror-like
surface!

• Do not move or adjust the DENEX Edge Detector II, without first turning off the
power! The green LED must be off!

• Service on the sensor should be made by qualified personnel only!

• The sensor must be installed in such way, that the laser does not hit a glossy,
mirror-like surface!

Visible Warning-LED
The green LED is the POWER-LED, which indicates that the laser is on!

Never move or adjust the sensor when the green LED is on!

User Manual DENEX Edge Detector II 12/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
9 TROUBLESHOOTING
The green LED (POWER) is OFF
• The sensor is not connected to +24V on pin 1 and 0V on pin 6 on the Tuchel
connector.
• If the sensor previously has been working, there could be transients damaging the
sensor. Make sure that the voltage is 24VDC and is well regulated.

The red LED (LASER-OFF) is lit constantly, and no laser is present

• Re-power the sensor. Check that the laser is lit. Is the laser turned off after a while? If
so, the laser settings have changed and the sensor must be sent back for repair.

The orange LED (OUTPUT-signal) is lit for every copy, but no pulse, or a different number of
pulses, is received by the connected equipment
• The interfacing is bad. Check the connection of the sensor. Is the sensor supposed to
source or sink the signal? Should the pulse be positive or negative? See chapter 3.3.
• Is the totalizer used, a battery powered device? It can be a problem because of the
voltage drop over the output transistor in the sensor. There is approx. 0.8V voltage drop
over emitter and collector at 2 mA which could mean that the totalizer does not see any
changes in state, i.e. from ”high” to ”low”. Check with a scope between pulse and ground.
• The opto-coupler in the sensor can be faulty.

There is an over count (too few copies in the bundles)

• Check the mechanical installation. The sensor must be parallel to the stream.
• Back-edges could be counted. Check by running one paper at a time, and see if
there is an extra pulse sent at the end of the paper.
• If the surface of the product is wavy, try tilting the sensor 5 - 10° according to figure
below.
• If there is a stitch or something near the edge, try a longer blocking or output pulse,
see chapter 4, ”DIP-SWITCH SETTINGS”

User Manual DENEX Edge Detector II 13/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
Some products are not counted (too many copies in the bundles)
• Check the mechanical installation. The sensor must be parallel to the stream.
• Check the Application setting; DIP 5-8.
• Check the interface. See previous page.
• If the product stream is very irregular, it could be that the sensor is blocking out
products coming too close. Try choosing an application with a shorter blocking.
See chapter 4, ”SOFTWARE FUNCTIONS”.
• Make sure that the stacker has not got an internal Blocking Zone which is set in a
way that it blocks out pulses from the sensor.
• If the product with the problem is very black and very thin, try lowering the sensor 10-
20 mm closer to the product stream.
• Are the products very tilted when they pass the sensor? The max angle allowed is
15° for a 0.25 mm product.

9.1 Maintenance at Regular Intervals

To ensure the best operation, by following the steps above:

• Clean the glass aperture with alcohol to remove ink dust.

• Remove any loose pieces of paper that can produce false counts

• Check that the target plate is still mounted the way it should be

User Manual DENEX Edge Detector II 14/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
10 RETURNING EQUIPMENT
If it is necessary to return a DENEX Edge Detector II for service, the following procedure
should be followed.

1. Tag the unit with the following:

• Company and contact person returning the item
• Phone, fax or email to the contact person for additional information
• Information regarding the malfunction and picture of installation. A good
description reduces trouble shooting cost.

If the unit has been disassembled, reassemble it, making certain that all hardware is in
place. Missing parts will be charged at spare part prices.

2. Carefully pack the unit and apply appropriate cautionary stickers.

3. Advice way of returning the unit: Post (DPD), UPS, DHL or other.

4. Return unit to your dealer or directly to Baumer (see address on back page).

11 WARRANTY
Baumer Electric AG gives a warranty to the customer for quality and suitability of its
products within the scope of its technical specifications. A warranty is only given according
to prior agreement for parts which are used as safety parts within the meaning of the EU
Machinery Directive. The guarantee of Baumer Electric AG is limited to replacement or
repair of defective parts and causes which occurred before the passing of risk. Liability for
further direct and indirect losses are excluded to the extent permissible at law, more
particularly, no compensation shall be owed for any incidental loss, loss of production etc.
The guarantee lapses in any event if the customer does not use original Baumer Electric
AG replacement parts. The guarantee is not valid in any instance where the goods have
been tampered with. The customer is under a duty to examine the consignment for
completeness and transport damage immediately on receipt. Any complaints in connection
with the product shall be made in writing without delay, and evidence of such incidence
must be produced. Complaints may be made about product defects during the complete
period of guarantee at any time before and/or after processing and/or re-sale, but they are
to be notified in writing enclosing the defective part without delay after emergence. The
customer may only invoke these guarantee conditions if he proves that the defects
emerged despite proper assembly and use. The guaranty period is 24 months from
dispatch from Baumer Electric AG. The period of guarantee for replacement parts or
repairs delivered under guarantee ends with the period for the products originally supplied.
Baumer Electric AG reserves the right to charge the processing costs for sales returns and
performance tests without claim to guarantee.

User Manual DENEX Edge Detector II 15/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
 12
31
A A

Version 2013-02, V1.6

175
19 3/4 Shaft or 19 mm shaft
12 APPENDIX

Suitable bracket available

User Manual DENEX Edge Detector II

from DENEX.
Part no. 53C6015

96
Size Diagram with Laser Beam Projection

16/20
92,7

www.baumer.com
15,5

70
55 65 M8

100
A-A

120
98,8

101,4

103,2 DENEX XENE D

DENEX Systems Technology AB
919-06a.CDR
DENEX CopySensor RW RW 980130
OUTLINE DRAWING LCS 919-06A

Frauenfeld, Switzerland
Baumer Electric AG
13 Supplements

User Manual DENEX Edge Detector II 17/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
User Manual DENEX Edge Detector II 18/20 Baumer Electric AG
Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
User Manual DENEX Edge Detector II 19/20 Baumer Electric AG
Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland
Baumer Electric AG
Sensor Solutions
Hummelstrasse 17
CH - 8500 Frauenfeld
Phone +41 (0) 527281122
Fax +41 (0) 527281110
sales.copycounter@baumer.com
www.baumer.com

Technical data subject to change Printed in Switzerland No. 11084088

User Manual DENEX Edge Detector II 20/20 Baumer Electric AG

Version 2013-02, V1.6 www.baumer.com Frauenfeld, Switzerland