Z240-E2-01+ZFV+UsersManual.qxd 13.01.2006 08:43 Seite 1 Cat. No. Z240-E2-03 Cat. No. Z240-E2-03 ZFV-C Smart Sensor with Ultra-High-Speed Color CCD Cameras User´s MANUAL Authorised Distributor: Cat. No. Z240-E2-03 Note: Specifications subject to change without notice.
Introduction This manual provides information regarding functions, performance and operating methods that are required for using the sensor. When using the ZFV-C Smart Sensor, be sure to observe the following: • The ZFV-C Smart Sensor must be operated by personnel knowledgeable in electrical engineering. • To ensure correct use, please read this manual thoroughly to deepen your understanding of the product. • Please keep this manual in a safe place so that it can be referred to whenever necessary.
SECTION 1 FEATURES SECTION 2 INSTALLATION & CONNECTION SECTION 3 FUNCTIONS AND OPERATIONS TO BE USED SECTION 4 SETTING OF INSPECTION CONDITION SECTION 5 SETTING ADDITIONAL FUNCTIONS SECTION 6 APPENDIX SECTION 7 APPLICATION AND SETTING User’s Manual Smart Sensor with Ultra-High-Speed Color CCD Cameras ZFV-C Series Introduction Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 INTRODUCTION APPLICATION CONSIDERATIONS (Please Read)
Introduction Introduction READ AND UNDERSTAND THIS DOCUMENT Please read and understand this document before using the products. Please consult your OMRON representative if you have any questions or comments. WARRANTY OMRON’s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.
Introduction THE PRODUCTS CONTAINED IN THIS DOCUMENT ARE NOT SAFETY RATED. THEY ARE NOT DESIGNED OR RATED FOR ENSURING SAFETY OF PERSONS, AND SHOULD NOT BE RELIED UPON AS A SAFETY COMPONENT OR PROTECTIVE DEVICE FOR SUCH PURPOSES. Please refer to separate catalogs for OMRON’s safety rated products.
Introduction Introduction DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown. ERRORS AND OMISSIONS The information in this document has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.
Introduction Meanings of Signal Words Introduction Meanings of Signal Words The following signal words are used in this manual. Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or may result in serious injury or death. Additionally there may be significant property damage. Meanings of Alert Symbols The following alert symbols are used in this manual. Indicates general prohibitions for which there is no specific symbol.
Introduction Precautions for Safe Use Introduction Precautions for Safe Use Please observe the following precautions for safe use of the products. (1) Installation Environment • Do not use the product in environments where it can be exposed to inflammable/ explosive gas. • Install the Amplifier Unit in such a way that the ventilation holes are not blocked. • To secure the safety of operation and maintenance, do not install the product close to high-voltage devices and power devices.
Introduction Precautions for Correct Use Introduction Precautions for Correct Use Please observe the following precautions to prevent failure to operate, malfunctions, or undesirable effects on product performance.
Introduction Precautions for Correct Use Introduction • Although the LCD display panel is manufactured by precision technology, it may have a minute amount of faulty pixels. This is due to the panel structure, and the panel is not faulty. (3) Orientation when Installing the Amplifier Unit To improve heat radiation, install the Sensor Controller only in the orientation shown below. Right Do not install the Amplifier Unit in the following orientations.
Introduction Precautions for Correct Use Introduction Editor’s Note Page Format Title of each section Header Overview Section 5 Setting Bank Related Conditions Cross-header Setting Bank Related Conditions Overview of the cross-header ZFV-C can hold up to eight sets of settings. These settings can be switched externally when changing the device setup. A set of these settings is called a “bank”. Setting the Bank Switching Method Index label Select how to switch banks.
Introduction Precautions for Correct Use Introduction ■ Meaning of Symbols Menu items that are displayed on the Amplifier Unit’s LCD screen are enclosed by brackets [aa]. ■ Visual Aids Indicates points that are important to ensure full product performance, such as operational precautions and application procedures. Indicates pages where related information can be found. Indicates information helpful in operation.
Introduction CONTENTS Meanings of Signal Words 5 Meanings of Alert Symbols 5 Alert Statements in This Manual 5 Precautions for Safe Use 6 Precautions for Correct Use 7 Editor’s Note 9 Page Format CONTENTS Menu Hierarchy 9 11 16 Section 1 FEATURES 19 Features 20 System Configuration 21 Part Names and Functions 24 Operation Mode 27 Setting Flow 28 Section 2 INSTALLATION & CONNECTION 31 About Installation and Connection 32 Amplifier Unit 32 Installing the Amplifier Unit 32 Ga
Introduction CONTENTS CONTENTS Section 3 FUNCTIONS AND OPERATIONS TO BE USED Switching the Display Content Characters Displayed on the LCD Monitor and Their Meanings 54 55 Key Operations for RUN Mode 57 Switching to Another Bank 58 Section 4 SETTING OF INSPECTION CONDITION Basic Knowledge for Operation 59 60 Displays of MENU/ADJ Mode and Key Operations 60 Teaching Flow 61 Inspecting by Pattern (PATTERN) 62 Basic Setting Procedure 63 CUSTOM Menu 64 Inspecting by the Size (Area) 66 Basic
Introduction CONTENTS 91 Setting Image Acquisition Conditions 92 Adjusting Light Intensity and Shutter Speed 92 Changing the Image Display Position (Partial Function) 93 Increasing the Sensor Head Sensitivity 93 Setting Conditions Related to Bank 94 Copying Banks 94 Clearing Banks 95 Setting the Bank Switching Method 95 Setting the System Environment 96 Changing the Measurement Speed 96 Selecting the Measurement Timing 97 Selecting the Teaching Mode from an External Device 97 Settin
Introduction CONTENTS CONTENTS Setting for Amplifier Unit Gang-Mount Specifying the Amplifier Unit to Input the Trigger 111 Setting the Presence of Sensor Head 111 Setting Output Content 111 Rules of Gang-Mounting 112 Data Route 113 Teaching Process when Gang-Mounting 114 Integrating Judgment Output 115 Restrictions when Gang-Mounting Amplifier Units 116 Section 6 APPENDIX 117 Troubleshooting 118 Error Messages and Corrective Actions 119 Q&A 120 Specifications and External Dimension
Introduction CONTENTS 149 Inspecting for the Presence of Electronic Components (Pattern) 150 Detecting Mixed Varieties of Campaign Seals (Area) 152 Inspecting Entry of Workpieces of Wrong Color (HUE) 156 Explanation of Color Related Functions 158 Color Pickup Function 158 Hue Indication Number 159 Revision History CONTENTS Section 7 APPLICATION AND SETTING 160 ZFV-C User’s Manual 15
Introduction Menu Hierarchy Introduction Menu Hierarchy Menu Hierarchy Items indicated by are displayed only when the EXP menu is selected. MENU mode TEACH Settings ITEM REG. PICK (*1) CUSTM [PATTERN/SEARCH] [PATTERN/MATCH] [AREA]:[AREA1/2] [AREA]:[AREA3] Default - SEARCH, MATCH p.62 AREA - AREA1, AREA2, AREA3 HUE - - WIDTH - - p.66 p.70 p.72 POSITION - - p.75 COUNT - - p.78 BRIGHT - - p.81 CHARA - CHARA1, CHARA2 p.84 SIZE - , p.61 MOVE - , p.
Introduction Menu Hierarchy [CHARA]:[CHARA1] MODE DTL Default Selection/Setting Range Page FILTER AUTO Same as [PATTERN/SEARCH/FILTER] METHOD DENAVE DENAVE, DENDEV p.65 p.83 FILTER AUTO Same as [PATTERN/SEARCH/FILTER] p.65 MODE NONE NONE, MODEL, EDGE MODEL - - p.88 p.88 EDGE MODE DARK LIGHT, DARK p.89 SEARCH AREA - - p.89 p.90 FILTER AUTO Same as [PATTERN/SEARCH/FILTER] p.65 MODEL DIV 1LINE NORMAL 1LINE SHORT, 1LINE NORMAL 1LINE, LONG, 2LINE SHORT 2LINE NORMAL p.
Introduction Menu Hierarchy Introduction Menu Hierarchy Settings SYSTEM 2 OUTPUT COM LOCK LINKSET (*8) Default Selection/Setting Range ON STATUS NG ON ONE SHOT OFF OFF, ON p.107 p.107 ON DELAY 0 0 to 255 p.108 OFF DELAY 0 0 to 255 p.109 OUTPUT TIME 0 0 to 255 p.108 TEACH IMAGE THROUGH THROUGH, FREEZE p.98 I/O MON - - p.99 LENGTH 8 7, 8 PARITY OFF OFF, ODD, EVEN p.102 p.102 STOP BIT 1 1, 2 p.102 BAUDRATE 38400 9600, 19200, 38400, 57600, 115200 p.
Section 1 FEATURES Section 1 FEATURES Features 20 System Configuration 21 Part Names and Functions 24 Operation Mode 27 Setting Flow 28 ZFV-C User’s Manual 19
Section 1 Features Features Section 1 FEATURES The ZFV-C sensor recognizes objects by its “surface”. Updating from the conventional monochrome sensor to this color sensor not only widens the choice of applications but also enables stable measurement. The ZFV-C also uses a 250,000-pixel CCD equivalent to that of a conventional machine vision sensor. This allows presence detection and recognition of different objects, which have up till now been performed by a human, to be executed fast and accurately.
Section 1 System Configuration System Configuration Sensor Head Detects workpieces as images.
Section 1 System Configuration ■ Amplifier unit expansion Section 1 FEATURES When amplifier units are gang-mounted, a wider range of applications can be supported by simultaneous processing of multiple areas and combination of measurement items can be combined. Setting for Amplifier Unit Gang-Mount p.110 ● Example 1 In this configuration, multiple areas in an image from a single Sensor Head are inspected and multiple inspection items are performed.
Section 1 System Configuration Data Storage Unit Personal Computer Section 1 FEATURES ● Example 3 Measurement images can be logged by connecting to data storage unit ZS-DSU. Set NG occurrence as a trigger to log before/after images and measurement values. This is useful for investigating the cause of defectives. Logged data is saved to the memory card inserted into the data storage unit, and can be easily loaded to a computer.
Section 1 Part Names and Functions Part Names and Functions Section 1 FEATURES The following describes the names and functions of parts on the Amplifier Unit and Sensor Head.
Section 1 Part Names and Functions No. Name Description Sensor Head connector This connector connects the Sensor Head. (10) Coupler This connector is used to connect two or more Amplifier Units. It is located on both sides of the Amplifier Unit. (11) I/O cable The I/O cable connects the Amplifier Unit to the power supply and external devices, such as timing sensors or programmable controllers. (12) USB port To connect a personal computer, connect a USB cable to this connector.
Section 1 Part Names and Functions ■ ZFV-SC150/SC150W Section 1 FEATURES (6) Ventilation film (1) Lighting part (5) Focus adjustment control (2) Receiver part (3) Connector (6) Ventilation film No. Name Description (1) Lighting part This area emits light. (2) Receiver part This area captures a image. (3) Connector This connector is connected to the Amplifier Unit. (4) Sensor Head mounting fixture This fixture is for mounting the Sensor Head.
Section 1 Operation Mode Operation Mode ADJ ESC MENU RUN Mode Section 1 FEATURES There are 3 ZFV-C operating modes as follows. Switch to the mode that you meet, before you start operation. To switch the operating mode, use the mode switch. Description MENU mode This mode is for executing teaching or setting up the measurement conditions. ADJ mode This mode is for setting the judgment threshold values. RUN mode This mode is for performing actual measurement.
Section 1 Setting Flow Setting Measurement Conditions, Checking Settings and Starting Measurement Section 1 FEATURES Preparation for Measurement Setting Flow Installation and Connection Connect the sensor head and amplifier unit. Section 2 INSTALLATION & CONNECTION p.32 Turn ON the power. Adjustment of Image Adjusts the image’s focus. Executing Teaching Execute teaching, and set the judgment criteria. Adjusting Threshold Values Adjust the threshold values used to make judgment on measured values.
Making Settings When Required Other Functions Customizing Measurement conditions Section 4 SETTING OF INSPECTION CONDITION p.59 Changing Image Acquisition Conditions Section 5 SETTING ADDITIONAL FUNCTIONS p.92 Setting Banks Section 3 FUNCTIONS AND OPERATIONS TO BE USED Switching to Another Bank p.58 Use two or more banks for setup changes. Section 1 FEATURES Advanced Operation Section 1 Setting Flow Section 5 SETTING ADDITIONAL FUNCTIONS Setting Conditions Related to Bank p.
Section 1 Setting Flow MEMO Section 1 FEATURES 30 ZFV-C User’s Manual
Section 2 INSTALLATION & CONNECTION 32 Amplifier Unit 32 Installing the Amplifier Unit 32 Gang-Mounting 36 About the I/O Cable 39 Timing Charts 42 Sensor Head 45 Affixing LED Warning Labels 45 Installing the Mounting Fixture 45 Installing the Sensor Head 47 Connecting the Sensor Head 51 ZFV-C User’s Manual Section 2 INSTALLATION & CONNECTION About Installation and Connection 31
Section 2 About Installation and Connection/Amplifier Unit About Installation and Connection ■ Checking the installation environment Read “Precautions for Safe Use” at the beginning of this manual, and check the installation environment. Section 2 INSTALLATION & CONNECTION ■ Checking the installation place Read “Precautions for Correct Use” at the beginning of this manual, and check the installation place. ■ About the power supply Before installing and connecting the Smart Sensor, be sure to turn it OFF.
Section 2 Amplifier Unit ● Installation procedure 1. Hook the connector end of the Amplifier Unit onto the DIN track. Hook on connector end Push the Amplifier Unit down onto the Hook on I/O cable end DIN track until the hook on the I/O cable side is locked. Push down until you hear it snap into place. Always hook the connector end of the Amplifier Unit on the DIN track first. Hooking the I/O cable end on the DIN track first may impair the mounting strength of the DIN track attachment.
Section 2 Amplifier Unit ■ Mounting on a panel The Panel Mount Adapters (sold separately ZS-XPM1) can be used to mount the Amplifier Unit on a panel. Panel Mount Adapters p.128 Section 2 INSTALLATION & CONNECTION 1. Push out the Amplifier Unit from the rear Panel of the panel towards the front. 2. Install the short Panel Mount Adapters on the four holes on the Amplifier Unit. 3.
Section 2 Amplifier Unit 4. Install the Amplifier Unit with Mount Adapters attached onto the panel from Panel the front. Take care not to pinch the I/O cable. Hook the hooks of the mounting bracket onto the two holes of the smaller Mount Adapters and tighten the screws. 6. Mounting bracket Section 2 INSTALLATION & CONNECTION 5. Make sure that the Amplifier Unit are firmly fixed on the panel.
Section 2 Amplifier Unit Gang-Mounting The following describes how to gang-mount Amplifier Units. ■ Mounting on a DIN track 1. Install a Amplifier Unit on a DIN track. Section 2 INSTALLATION & CONNECTION p.33 2. Open the connector cover of each Amplifier Unit. Controller Link Unit Slide the cover to remove. 3. Insert the Controller Link Unit into the connector on the one of Amplifier Units. 4. Slide the other Amplifier Unit, and insert into the connector on the Controller Link Unit.
Section 2 Amplifier Unit ● Mounting on a panel The Panel Mount Adapters (sold separately ZS-XPM1/XPM2) can be used to mount the Amplifier Unit on a panel. Panel Mount Adapters p.128 Install a Amplifier Unit on a DIN track. p.33 When mounting on a panel, be sure to install the DIN track on the rear side of the Amplifier Unit for support. 2. Push out the Amplifier Unit from the rear of the panel towards the front. Panel 3. Section 2 INSTALLATION & CONNECTION 1.
Section 2 Amplifier Unit 4. Install the long Mount Adapters on the Panel Mount Adapters two holes on the small Mount Adapter. Install the long Mount Adapters only on both sides of gang-mounted Amplifier Units. Section 2 INSTALLATION & CONNECTION Panel Mount Adapters 5. Install the Amplifier Unit with Mount the front. Take care not to pinch the I/O cable. ZF V ZF V 6. Hook the hooks of the mounting fixture onto the two holes of the smaller Mount Adapters and tighten the screws.
Section 2 Amplifier Unit About the I/O Cable The following shows the leads that comprise the I/O cable. (1) Power supply Blue (2) GND Black (3) OUTPUT*1 Orange (4) ENABLE Light blue (5) ERROR Yellow (6) TEACH*1 Pink (7) TRIG*1 Gray (8) BANK1*1 Green (9) BANK2*1 Red (10) BANK3*1 Purple White Unused Unused *1: Enabled only in the RUN mode (1) Power Supply This connects the power supply. Use a DC power supply with safe extra-low-voltage circuits to prevent high voltage.
Section 2 Amplifier Unit (6) TEACH (teaching input) There are two teaching modes, workpiece stop teaching and workpiece move teaching. These teaching modes can be selected in the menu. Selecting the Teaching Mode from an External Device p.97 (7) TRIG (measurement trigger input) Section 2 INSTALLATION & CONNECTION There are two measurement modes, synchronous measurement and continuous measurement. Which mode of measurement is to be performed in is selected in the menu.
Section 2 Amplifier Unit ■ I/O Circuit diagrams ● NPN output type (ZFV-CA40) Brown Power (24 VDC) Black OUTPUT Load Orange ENABLE Load Internal circuit Light blue ERROR 24 VDC Blue GND(0V) Yellow TEACH Pink TRIG Gray BANK1 Green BANK2 Red BANK3 Section 2 INSTALLATION & CONNECTION Load ● PNP output type (ZFV-CA45) Brown Power (24 VDC) Yellow TEACH Pink TRIG Gray BANK1 Internal circuit Green BANK2 Red BANK3 Blue GND(0 V) Light blue ERROR 24 VDC Orange ENABLE Load Black OUTPUT Lo
Section 2 Amplifier Unit Timing Charts The following shows the timing charts when communication is performed with external devices. ■ Measurement Section 2 INSTALLATION & CONNECTION ● Continuous measurement Measurement is performed continuously for the duration that the TRIG signal is ON. The measurement result is updated, and output to external devices at each measurement cycle.
Section 2 Amplifier Unit ■ Teaching ● Workpiece stop teaching Teaching processing is performed according to TRIG signal input after the TEACH signal is input. Measurement is not performed while teaching is being performed. Do not move the workpiece until teaching is completed. OFF ON TRIG OFF ON ENABLE OFF ON ERROR OFF ON (1) Section 2 INSTALLATION & CONNECTION TEACH (8) (4) (5) (2) Teaching in progress (6) (7) (1) Turn the TEACH signal ON.
Section 2 Amplifier Unit ● Workpiece move teaching Use this teaching mode when the object cannot be stopped. Teaching processing is divided up and performed in synchronous with the TRIG signal input after the TEACH signal is input. Teaching must be processed eight times. Measurement is not performed while teaching is being performed. Min.
Section 2 Sensor Head Sensor Head This section describes how to install and connect the Sensor Head. Affixing LED Warning Labels • Label affixing example Warning label Warning label WARNING LED RADIATION DO NOT STARE INTO BEAM Max.5mW 1msec 400-700nm Section 2 INSTALLATION & CONNECTION Affix warning labels (supplied with the sensor) to appropriate positions (e.g. cable) near the sensor.
Section 2 Sensor Head 1. Align the two hooks on one side of the Grooves mounting fixture with the two grooves on the Sensor Head body (light emitting side). Section 2 INSTALLATION & CONNECTION 2. Hook Push the other hook. Push down until you hear it snap into place. 3. Make sure that the mounting fixture is firmly fixed on the Sensor Head.
Section 2 Sensor Head Installing the Sensor Head This section describes how to install the Sensor Head. ■ Setting distance Workpiece • ZFV-SC10 Setting distance L Detection range H Setting distance L (mm) 100 30 4 Detection range H (mm) Setting distance L (mm) 5 34 6 37 7 40 8 44 9 49 Section 2 INSTALLATION & CONNECTION The following graphs show the relationship between detection range and setting distance for each model of Sensor Head.
Section 2 Sensor Head • ZFV-SC90 Setting distance L (mm) Detection range H (mm) Setting distance L (mm) 160 100 Section 2 INSTALLATION & CONNECTION 40 40 70 100 Detection range H (mm) 67 55 76 60 86 65 95 70 104 75 114 80 123 85 132 90 142 • ZFV-SC150 Setting distance L (mm) Detection range H (mm) Setting distance L (mm) 240 180 100 80 120 160 Detection range H (mm) 48 50 ZFV-C User’s Manual 90 115 95 124 100 134 105 143 110 152 115 162 120 171 125 180 130
Section 2 Sensor Head ■ Adjusting the Sensor Head Focus 1. Set the menu selector switch to “STD ADJ menu” and the mode selector switch to “MENU mode”. Section 2 INSTALLATION & CONNECTION 2. MENU RUN Set the reference workpiece in place. Reference workpiece 3. Place the cursor on and press the MENU SET Key. TEACH 4. Adjust the camera’s setting distance. Refer to the graph and set the camera in a position so that the area to be checked is within the detection area (LCD monitor).
Section 2 Sensor Head 5. Turn the focus adjustment control to the Focus adjustment control left and right to adjust the focus. For ZFV-SC10/SC50/SC50W Section 2 INSTALLATION & CONNECTION • Turn to right: Focuses to the far side. • Turn to left: Focuses to the near side. Default is focus set at furthest point. First turn the focus adjustment control slightly to the left and right, to make sure that the Focus adjustment control is not at the upper or lower limit positions.
Section 2 Sensor Head Connecting the Sensor Head This section describes how to connect the Amplifier Unit. • Before connecting/disconnecting the Sensor Head, make sure that the Amplifier Unit is turned OFF. The Smart Sensor may break down if the Sensor Head is connected or disconnected while the power is ON. ■ Connecting the Sensor Head Insert the Sensor Head connector into the Sensor Head connector of the Amplifier Unit. Ferrite core Attach the ferrite cores on the cable of the Sensor Head.
Section 2 Sensor Head ■ Connecting the Optional Lighting Unit This optional lighting unit can be mounted to the rear connector of the sensor head (ZFV-SC50/SC50W/SC90/SC90W) with a single motion, and no power supply is required for the unit. Section 2 INSTALLATION & CONNECTION 52 Connector of the optional lighting unit ZFV-C User’s Manual Remove the cap from the LIGHT connector on the rear of the sensor head.
Section 3 FUNCTIONS AND OPERATIONS TO BE USED 54 Key Operations for RUN Mode 57 Switching to Another Bank 58 ZFV-C User’s Manual Section 3 FUNCTIONS AND OPERATIONS TO BE USED Switching the Display Content 53
Section 3 Switching the Display Content Switching the Display Content Display contents on the LCD monitor can be changed in the RUN mode. Content is switched in the following order each time the TEACH/VIEW key is pressed. Display the measured values suitable for your application. The measurement time differs according to the type of display image. The measurement time for “only image display” is the fastest.
Section 3 Switching the Display Content Characters Displayed on the LCD Monitor and Their Meanings Characters in parentheses are the characters that are displayed in the enlarged display mode. ■ Items displayed in common at [ITEM] Display Characters Details Judgment result (OK/NG) TH Judgment threshold value In the case of the upper/lower limits, XX - YY (lower limit - upper limit) is displayed. AVE Average value of measurement result DRANGE Min. and max. of measurement result XX - YY (min.
Section 3 Switching the Display Content ● POSITION Display Characters GAP Details Deviation from reference position ● COUNT Display Characters CNT Details Count number ● BRIGHT Section 3 FUNCTIONS AND OPERATIONS TO BE USED 56 Display Characters Details DENAVE Density average value DENDEV Density distribution value ● CHARA1 Display Characters DENDEV ZFV-C User’s Manual Details Density distribution value
Section 3 Key Operations for RUN Mode Key Operations for RUN Mode Control keys Description TEACH/VIEW key Function keys Switches the display content. A B C D A: Switches the image display conditions. B: (Not used) C: Performs measurement again. D: (Not used) ← LEFT key → RIGHT key In [BRIGHT], the display content is switched between “average density value” and “density distribution value”. ↑UP key ↓ DOWN key Not used. SET key Not used. ESC key Not used.
Section 3 Switching to Another Bank Switching to Another Bank ZFV-C can hold up to eight sets of settings. These settings can be switched externally according as inspection condition. A set of these settings is called a “bank”. A bank also contains the threshold value set in ADJ mode. • What is a Bank? Each set of measurement settings is Threshold Registered as a bank. Threshold Section 3 FUNCTIONS AND OPERATIONS TO BE USED BANK1 BANK2 BANK3 ■ Switching to another bank by control keys 1.
Section 4 SETTING OF INSPECTION CONDITION Basic Knowledge for Operation 60 60 Teaching Flow 61 Inspecting by Pattern (PATTERN) 62 Inspecting by the Size (Area) 66 Inspecting by Color (HUE) 70 Inspecting by Width (WIDTH) 72 Inspecting by Position (POSITION) 75 Inspecting by Count (COUNT) 78 Inspecting by Brightness (BRIGHT) 81 Detecting Presence of Character String (CHARA) 84 ZFV-C User’s Manual Section 4 SETTING OF INSPECTION CONDITION Displays of MENU/ADJ Mode and Key Operations 59
Section 4 Basic Knowledge for Operation Basic Knowledge for Operation Displays of MENU/ADJ Mode and Key Operations Make setups by the control keys while looking at the menus and the image displayed on the LCD monitor. The details that are displayed differ according to the operating mode. • MENU mode • ADJ mode Bank No.
Section 4 Basic Knowledge for Operation Teaching Flow TEACH/SEARCH MENU Adjust the image's focus and sensor head's mount position while monitoring the image. Activating the MENU mode and opening the teaching screen ITEM TEACH TEACH/ITEM REG. Selecting the inspection item [ITEM] PATTERN TEACH/REG. PTRN AREA HUE WID POSI CNT BRGT CHARA TEACH/REG. Enclose the area to be inspected using a rectangular box. The size and position of the box can be adjusted. Area adjustment [REG.
Section 4 Inspecting by Pattern (PATTERN) Inspecting by Pattern (PATTERN) Inspects “presence/absence” of the workpiece and judges whether the type of workpiece is correct. There are two measurement items for [PATTERN]: [SEARCH] and [MATCH]. ● Search Judgment is performed by whether the registered model is or is not in the inspected area. This item works with workpieces tilted to an angle of ±45°.
Section 4 Inspecting by Pattern (PATTERN) Basic Setting Procedure ■ Teaching The area to be inspected needs to be enclosed by a rectangular box, then teach it. The selected image in the area is registered as the inspection reference (model). Measurement is unstable when there are two or more of the same pattern. Register unique pattern in the screen or restrict the search range.
Section 4 Inspecting by Pattern (PATTERN) CUSTOM Menu Items that can be customized Items that can be customized Page Items Related to pattern Changing the search area p.64 Setting the rotation range of a workpiece (only when [SEARCH] is selected) p.64 Items related to color Changing the filter color p.65 Performing color check p.65 Teaching brightness p.
Section 4 Inspecting by Pattern (PATTERN) ■ Items related to color ● Changing the filter color By default (AUTO), a color filter that increases the contrast of “area of the largest color group” and “area of the second largest color group” located inside the area will be selected automatically. If the contrast of the desired image is not increased with [AUTO], the filter color can be changed to suit the image.
Section 4 Inspecting by the Size (Area) Inspecting by the Size (Area) Select this item to inspect objects by size (area). There are two measurement items for [AREA]: [AREA1] and [AREA2]. ● AREA1 Make a judgment based on the total area of the picked-up colors (max. 4 colors). This method is useful when the workpiece is not stationary and it has halation or printed characters.
Section 4 Inspecting by the Size (Area) ● AREA3 Measure the area by specifying the measurement target according to brightness, not color, difference. (Binary image) This method is suitable when detecting a glossy metal surface and making a presence/ absence judgment according to the brightness difference, not to the color difference.
Section 4 Inspecting by the Size (Area) Basic Setting Procedure ■ Teaching Teaching is performed after the object and color to be inspected are specified. Inspection area setting AREA2 Color Selection OK TEACH/PICK 1 1 point ITEM Teaching point REG. PICK. SEL :VOID D:HIST Application and Setting Examples p.152 Section 4 SETTING OF INSPECTION CONDITION ■ Adjusting the threshold level Threshold values are adjusted to determine the range for OK judgments.
Section 4 Inspecting by the Size (Area) CUSTOM Menu Items that can be customized Items that can be customized Page Items related to color Teaching brightness p.65 Items related to monochrome (When AREA3 is selected) Selecting the target color p.69 Setting binary levels p.69 ■ Items Related to Monochrome This CUSTOM menu is provided when AREA3 is selected. X MENU mode-[TEACH]-[CUSTM]-[COLOR] Setting WHITE (default) Details Select which part of the measurement area is to be set as white pixels.
Section 4 Inspecting by Color (HUE) Inspecting by Color (HUE) This item inspects color difference of plain-colored workpieces. If there are two or more colors in the area, the color of the largest area will be the subject of inspection. Example: Cap color inspection HUE OK HUE NG OK Section 4 SETTING OF INSPECTION CONDITION NG due to wrong color Basic Setting Procedure ■ Teaching Enclose the area to be inspected using a square box, and then perform teaching.
Section 4 Inspecting by Color (HUE) ■ Adjusting the threshold level ● Switching to ADJ mode ● Adjusting the Threshold Level HUE OK ADJ MENU RUN TH [ 5 10] Measured values Threshold UP/DOWN keys: Change values. Setting item 0 to 509 Details of Adjustment Threshold for color difference needs to be set. The judgment will be OK if the measured color difference is below the threshold. Hue Indication Number p.
Section 4 Inspecting by Width (WIDTH) Inspecting by Width (WIDTH) This item inspects the width or gap of workpieces. It is suitable for applications such as checking lead bend and label position. Example: Inspection of capacitor lead gap Section 4 SETTING OF INSPECTION CONDITION WIDTH OK WIDTH NG WIDTH NG OK NG due to too wide lead gap NG due to too narrow lead gap Basic Setting Procedure ■ Teaching Enclose the area to be inspected using a rectangular box and then perform teaching.
Section 4 Inspecting by Width (WIDTH) ■ Adjusting the threshold level ● Switching to ADJ mode ● Adjustment of edge width WIDTH ● Adjustment of edge width WIDTH OK OK Edge level ADJ MENU RUN 120 L: [ 100] H:[ 150] Upper/lower limit Lower limit Measured values :LEV :SEL EDGE LEV [ 50] Upper limit Edge level • When edge detection direction is ←→ LEFT/RIGHT keys: Switch edge. UP/DOWN keys: Change values. LEFT/RIGHT keys: Select upper limit/lower limit. UP/DOWN keys: Change values.
Section 4 Inspecting by Width (WIDTH) ■ Items related to edge detection Set the direction in which edges are searched and the density level. Example) Teaching area To inspect this width EDGE MODE: DARK DIRECTION: ←→ ● Selecting the color of edges Select the direction of density change for the edge to be detected. Section 4 SETTING OF INSPECTION CONDITION X MENU mode-[TEACH]-[CUSTM]-[EDGE MODE] Setting Details DARK Dark areas shown in the filtered monochrome image are assumed to be edges.
Section 4 Inspecting by Position (POSITION) Inspecting by Position (POSITION) This item is used to check the position of the workpiece. The edge of the workpiece is detected, and judgment is performed by comparing those edge coordinates against reference coordinates. This item is suitable for applications such as checking presence/position of sealing tape and checking label position.
Section 4 Inspecting by Position (POSITION) ■ Adjusting the threshold level ● Switching to ADJ mode ● Adjustment of edge position ● Adjustment of edge level Edge level POSITION OK POSITION OK ADJ MENU RUN GAP 120 [ 150] Measured values Threshold Amount of shift :LEV CHANGE EDGE LEV [ 50] Edge level • When edge detection direction is → UP/DOWN keys: Change values. UP/DOWN keys: Change values.
Section 4 Inspecting by Position (POSITION) ■ Items related to edge detection Set the direction in which edges are searched and the change in density. Example) To detect this position EDGE MODE: DARK DIRECTION: → ● Selecting the color of edges Select the direction of density change for the edge to be detected. X MENU mode-[TEACH]-[CUSTM]-[EDGE MODE] Details DARK Dark areas shown in the filtered monochrome image are assumed to be edges.
Section 4 Inspecting by Count (COUNT) Inspecting by Count (COUNT) Select this item when counting the number of workpieces. The edges in the teaching area are detected, and judgment is performed by comparing the number of edges with a reference value. This item is suitable for applications such as inspecting the number of cookies in a box, checking the number of leads and counting cables.
Section 4 Inspecting by Count (COUNT) ■ Adjusting the threshold level ● Switching to ADJ mode ● Adjustment of edge level ● Adjustment of count COUNT OK COUNT OK ADJ MENU RUN L:[ 5] Lower limit 5 5] H:[ Measured values : LEV CHANGE EDGE LEV: [ 50] Edge level Upper limit • When edge detection direction is → UP/DOWN keys: Change values. UP/DOWN keys: Change values. • When edge detection direction is ↓ LEFT/RIGHT keys: Change values.
Section 4 Inspecting by Count (COUNT) ● Selecting the color of edges Select the direction of density change for the edge to be detected. X MENU mode-[TEACH]-[CUSTM]-[EDGE MODE] Setting Details DARK Dark areas shown in the filtered monochrome image are assumed to be edges. LIGHT (default) Light areas shown in the filtered monochrome image are assumed to be edges. ● Selecting the edge detection direction Select the direction in which edges are searched.
Section 4 Inspecting by Brightness (BRIGHT) Inspecting by Brightness (BRIGHT) Select this item to detect brightness (density) or scratches/dirt on plain workpieces. It is suitable for applications such as checking for dirt on battery surface, scratches on sheets and checking whether LEDs light up properly. Example: Inspection for Dirt on Battery Surface OK OK BRIGHT NG NG due to dirt Basic Setting Procedure ■ Teaching Enclose the area to be inspected using a rectangular box and then perform teaching.
Section 4 Inspecting by Brightness (BRIGHT) ■ Adjusting the threshold level ● Switching to ADJ mode ● Adjustment of density deviation value ● Adjustment of average density value BRIGHT OK BRIGHT OK ADJ MENU RUN 200 L: [ 200] H:[ 220] A Upper/lower limit Lower limit Measured values Upper limit Upper/lower limit Lower limit Section 4 SETTING OF INSPECTION CONDITION 82 Range Measured values Upper limit LEFT/RIGHT keys: Select upper limit/ lower limit. UP/DOWN keys: Change values.
Section 4 Inspecting by Brightness (BRIGHT) ■ Items related to brightness ● Changing the detection content Select the content to be inspected. X MENU mode-[TEACH]-[CUSTM]-[METHOD] Setting Details AVERAGE (default) Inspect by brightness (average density value). Whether an object is lighter or darker is detected by referring to the density at teaching. DEVIATION Inspect by (density deviation) in density. Select this to detect scratches or dirt.
Section 4 Detecting Presence of Character String (CHARA) Detecting Presence of Character String (CHARA) Select this item to check for presence of character strings. There are two measurement items for [CHARA]: [CHARA1] and [CHARA2]. ● CHARA1 Select this item to check for presence of the entire character string printed on plain background. Judgment is performed by monitoring changes in density (brightness) of the registered character string. Errors in characters, missing dots, etc. cannot be detected.
Section 4 Detecting Presence of Character String (CHARA) Basic Setting Procedure ■ Teaching Enclose the area to be inspected using a rectangular box and then perform teaching. Inspection area setting CHARA1 Teaching OK 50 505 Teaching area for [CHARA] For the teaching area when the printing position is out of position, set to an area in which the characplain background.
Section 4 Detecting Presence of Character String (CHARA) ■ Adjusting the threshold level ● CHARA1 ●Switching to ADJ mode ● Adjustment of correlation value CHARA1 OK ADJ 505 MENU RUN TH [ 80 60] Measured values Density distribution value UP/DOWN keys: Change values. Section 4 SETTING OF INSPECTION CONDITION Setting item Details of Adjustment Density distribution value 0 to 100 ● This is the value that is judged as OK when the density deviation value during teaching is taken to be 100%.
Section 4 Detecting Presence of Character String (CHARA) CUSTOM Menu Items that can be customized Items that can be customized Items related to char- Setting the model registration conditions for characters (Only when acter [CHARA2] is selected) Selecting whether or not to perform position compensation Items related to color Page p.87 p.88 Changing the search area p.90 Raising detection stability (Only when [CHARA2] is selected) p.90 Changing the filter color p.
Section 4 Detecting Presence of Character String (CHARA) ● Selecting whether or not to perform position compensation Set position compensation for improving detection accuracy in the following instances: When printed text is out of position When there is a pattern in the detection range 2004/09/24 2004/09/24 X MENU mode-[CUSTM]-[MODE] Setting Details Section 4 SETTING OF INSPECTION CONDITION NONE The position is not corrected. MODEL The model is used to correct the position.
Section 4 Detecting Presence of Character String (CHARA) • Specifying edge detection conditions Set the edge detection conditions when [EDGE] is selected for [MODE]. Set the direction in which edges are searched and the density level. Example) To correction position by this edge 2004/09/24 EDGE MODE: BLACK EDGE: ↓ X MENU mode-[CUSTM]-[MODE DTL]-[EDGE MODE] Setting Details DARK (default) Dark areas shown in the filtered monochrome image are assumed to be edges.
Section 4 Detecting Presence of Character String (CHARA) ● Changing the search area Change the area to search edges or the model. Specify the top left coordinate and bottom left coordinate of the area. Search area Search area 2004/09/24 2004/09/24 X MENU mode-[CUSTM]-[MODE DTL]-[SEARCH AREA] Section 4 SETTING OF INSPECTION CONDITION 90 When searching edges Measurement can be performed only when the search area contains an edge.
Section 5 SETTING ADDITIONAL FUNCTIONS Setting Image Acquisition Conditions 92 Adjusting Light Intensity and Shutter Speed 92 Changing the Image Display Position (Partial Function) 93 Increasing the Sensor Head Sensitivity 93 Setting Conditions Related to Bank 94 94 Clearing Banks 95 Setting the Bank Switching Method 95 Setting the System Environment 96 Changing the Measurement Speed 96 Selecting the Measurement Timing 97 Selecting the Teaching Mode from an External Device 97 Setting Scre
Section 5 Setting Image Acquisition Conditions Setting Image Acquisition Conditions Adjusting Light Intensity and Shutter Speed The intensity of the light from Sensor Head and shutter speed can be adjusted. [AUTO] is selected as the default setting. X MENU mode-[IMAGE]-[CONTRAST] Setting Details AUTO (default) Light intensity and shutter speed are adjusted automatically. FIX LIGHT The light intensity can be set for each side. 0: Out, 1 to 5: Light intensity increases according to the number.
Section 5 Setting Image Acquisition Conditions Changing the Image Display Position (Partial Function) ZFV-C allows you to increase the processing speed by narrowing the image acquisition area. The image area can be moved, when measurement speed is FAST mode (1/2 screen) or MAX mode (1/4 screen). Changing the Measurement Speed p.96 The center of the image is selected just after the measurement speed is changed. Can be moved to the desired position vertically.
Section 5 Setting Conditions Related to Bank Setting Conditions Related to Bank ZFV-C can hold up to eight sets of settings. These settings can be switched according to inspection conditions. A set of these settings is called a “bank”. Copying Banks Copy the settings of one bank to another bank. The following example shows the procedure for copying the settings of BANK 1 to BANK 2. X MENU mode-[SYS1]-[BANK SET]-[COPY] 1. Make the settings that are required to perform inspection at BANK 1 (copy source).
Section 5 Setting Conditions Related to Bank Clearing Banks “Clearing” deletes the settings of the selected bank number. X MENU mode-[SYS1]-[BANK SET]-[CLEAR] Settings Description EXECUTE Executes clear. CANCEL Cancels clear. [SYS1], [SYS2] settings and RUN mode display settings will not be cleared. Setting the Bank Switching Method Select how to switch banks. Setting Description KEY (default) Banks are switched by the control keys on Amplifier Unit.
Section 5 Setting the System Environment Setting the System Environment Changing the Measurement Speed The processing speed can be increased by narrowing the image acquisition area. Change the measurement speed according to the size of workpiece and required speed. NORMAL FAST MAX Entire image 1/2 1/4 X MENU mode[SYS1]-[SPEED] Setting Section 5 SETTING ADDITIONAL FUNCTIONS 96 Details NORMAL (default) Acquires the entire image. (13 ms) FAST Narrows the image acquisition area to 1/2.
Section 5 Setting the System Environment Selecting the Measurement Timing Set the timing that measurement is executed. X MENU mode-[SYS1]-[MEAS TYPE] Setting Details TRIG (default) Synchronous measurement Measurement is performed in synchronous with the change in state of the external TRIG signal from OFF to ON. CONTINUE Continuous measurement Measurement is repeatedly performed for the duration that the TRIG signal is ON.
Section 5 Setting the System Environment Setting/Cancelling the Eco Mode Whether or not to darken the screen when a preset time has passed without any operation. We recommend setting this mode to [ON] to prevent the brightness of the LCD screen from being impaired. X MENU mode-[SYS1]-[ECO MODE] Setting Details ON (default) Sets the Eco mode. The screen darkens when three minutes continue without any operation. OFF Cancels the Eco mode setting.
Section 5 Setting the System Environment I/O Monitor Function This is a function to check the status of I/O signals. SYS2/I/O MON Signal name : TRIG TEACH : : BANK OUTPUT : ENABLE : ERROR : OK 0 0 000 0 0 1 Signal status (0: OFF, 1: ON) X MENU mode-[SYS2]-[I/O MON] Setting TRIG Details Displays ON/OFF status of TRIG signal. (0: OFF, 1: ON) TEACH Displays ON/OFF status of TEACH signal. (0: OFF, 1: ON) BANK Displays ON/OFF status of BANK signal.
Section 5 Setting the System Environment Correcting White Balance Due to influences by sensor head’s surrounding and lighting, the image taken by the camera sometimes contains colors even if the object is white. The function to correct the color of a white object so that the object is displayed as white is called white balance. X MENU mode-[SYS2]-[WHITE BAL] 1. Display a white object (e.g. paper, cloth) on the monitor. 2. Press the TEACH/VIEW key while “OK” is displayed at the lower left of the screen.
Section 5 Setting the System Environment Initializing Measurement Data Current and past measurement average values, measurement count and other measurement data can be cleared without restarting. Data to be cleared are the items displayed in the following screen at RUN mode. SEARCH OK JG : OK SCORE : 98 TH : 60 AVE : 0 DRANGE : 0-100 MCONT : 2 NG% : 1.000 TIME : 144 Meaning of display contents p.55 X MENU mode-[SYS2]-[MEAS CLEAR] Setting Description EXECUTE Initialize measurement data.
Section 5 Setting USB/RS-232C Communication Specifications Setting USB/RS-232C Communication Specifications Set the communication specifications of the Amplifier Unit according to those of external devices. For details on communication commands, refer to the “Communication Command Reference” (provided separately). For the “Communication Command Reference”, contact OMRON sales staff. Before connecting/disconnecting external devices, make sure that the Amplifier Unit is turned OFF.
Section 5 Setting USB/RS-232C Communication Specifications RS-232C Connection ■ Connection 1. Insert one end of the RS-232C cable to the RS-232C connector on the Amplifier Unit. 2. Insert the other end of the RS-232C cable to the RS-232C connector of the external device. Section 5 SETTING ADDITIONAL FUNCTIONS ● RS-232C cable for connecting a programmable controller RS-232C cable • ZS-XPT2 (cable length: 2 m) Amplifier unit side PLC side (Note 1) Fitting section 10 1 1 2 6 NC Pin No.
Section 5 Setting USB/RS-232C Communication Specifications ● RS-232C cable for connecting a personal computer • ZS-XRS2 (cable length: 2 m) Amplifier unit side PC side (PC/AT compatible) (Note 1) 1 2 3 4 5 Fitting section 10 1 6 7 NC Pin No. 1 Pin No.
Section 5 Restricting Operations (Lock Function) Restricting Operations (Lock Function) Setting the Lock Function Set the lock function to restrict switch and key operations. By restricting switch and key operations, unintended changes in settings can be prevented. Three types of operations, "mode switch", "key input", and "TEACH signal input", can be locked. X MENU mode-[SYS2]-[LOCK] Standard value Description Operation of the mode switch (MENU/ADJ/RUN) is restricted.
Section 5 Restricting Operations (Lock Function) Starting/Cancelling the Lock Function Set the [PASS NUMBER] required for cancelling the lock function before starting the function. ■ Starting 1. In the RUN mode, press the ESC key for at least two seconds. A start confirmation message will appear. The start confirmation message will not appear unless an item to be restricted is set. 2. Select [EXECUTE]. The lock function is started.
Section 5 Changing OUTPUT Signal Output Conditions Changing OUTPUT Signal Output Conditions Selecting the ON Conditions Set whether to turn the OUTPUT signal ON when OK is judged or when NG is judged. X MENU mode-[SYS2]-[OUTPUT]-[ON STATUS] Setting Details OK ON Turns the OUTPUT signal ON when OK is judged. NG ON (default) Turns the OUTPUT signal ON when NG is judged.
Section 5 Changing OUTPUT Signal Output Conditions ■ Selecting One-Shot output ON/OFF Set whether or not to enable one-shot output on the OUTPUT signal. X MENU mode-[SYS2]-[OUTPUT]-[ONE SHOT] Setting Details OFF (default) One-shot output is not performed. ON One-shot output is performed. When one-shot output is set to [ON], the OFF delay time setting is disabled. ■ Setting the One-Shot output Time OUTPUT turns ON for the preset time from when the OUTPUT signal turns ON.
Section 5 Changing OUTPUT Signal Output Conditions Setting the OFF Delay Time Set this item to delay the timing that the OUTPUT signal turns OFF. OUTPUT ON at OK judgment in continuous measurement Judgment NG OUTPUT Judgment OK Judgment NG OFF ON Delay time X MENU mode-[SYS2]-[OUTPUT]-[OFF DELAY] Setting 0 to 255 (default: 0) Details Set the time (ms) to delay turning OFF of the OUTPUT signal.
Section 5 Setting for Amplifier Unit Gang-Mount Setting for Amplifier Unit Gang-Mount The gang-mount related menus are displayed only when Amplifier Unit are gang-mounted. These settings must be made to each Amplifier Unit. ● Example 1: 1 sensor head + multiple amplifier units Example of detection of input image from 1 sensor head with multiple amplifier units. • To detect multiple areas such as a 4-sided POSITION, multiple item SEARCH, etc.
Section 5 Setting for Amplifier Unit Gang-Mount Specifying the Amplifier Unit to Input the Trigger Set whether or not to input the TRIG signal to an Amplifier Unit. X MENU mode-[SYS2]-[LINKSET]-[TRIG] Setting Details I/O (default) Set to only the Amplifier Unit to which the TRIG signal is to be input. LINK Synchronizes to the TRIG signal from the Amplifier Unit gang-mounted on the right side. All the Amplifier Units except for the rightmost one are set to [LINK] automatically.
Section 5 Setting for Amplifier Unit Gang-Mount Rules of Gang-Mounting Item No. of Amplifier Units connectable 5 or less (power must be supplied to each Amplifier Unit) No.
Section 5 Setting for Amplifier Unit Gang-Mount Data Route ■ Measurement image The measurement image flows from the right-side amplifier unit towards the left-side. Image input timing delays do not occur. ■ I/O signal OUTPUT signal TRIG signal ENABLE signal ZFV-C User’s Manual Section 5 SETTING ADDITIONAL FUNCTIONS The TRIG signal flows from the right-side amplifier unit towards the left-side. Input timing delays do not occur.
Section 5 Setting for Amplifier Unit Gang-Mount Teaching Process when Gang-Mounting ■ Teaching (key input) from MENU mode Enter the teaching screen from the host device and press the TEACH key to teach all clients in the teaching screen where the host device is added. Enter the teaching screen for the client only and press the TEACH key to teach only this client.
Section 5 Setting for Amplifier Unit Gang-Mount Integrating Judgment Output Judgment result output (OUTPUT) of gang-mounted amplifier units can be integrated. Setting output content p.111 ■ When all amplifier unit measurement results are integrated (ALL) Select [ALL] to integrate measurement results of all gang-mounted amplifier units and output from amplifier units (host device) where TRIG signals are input. Obtain OUTPUT signal after ENABLE signal is set to ON.
Section 5 Setting for Amplifier Unit Gang-Mount Restrictions when Gang-Mounting Amplifier Units ■ ZFV-A_ _ Gang-mounting units The ZFV-A_ _ units cannot be gang-mounted. ■ ZFV-CA Gang-mounting multiple units To use two or more ZFV-CA units by gang-mounting them to each other, the following hardware and software are required: Hardware: Amplifier unit with serial number; ZFV-CA40: 0218206 or bigger ZFV-CA45: 0003206 or bigger Software: Firmware version 1.
Section 6 APPENDIX 118 Error Messages and Corrective Actions 119 Q&A 120 Specifications and External Dimensions 121 LED Safety Precautions for Using Laser Equipment 135 Requirements from Regulations and Standards 136 Updating the Firmware 140 Version upgrade information 145 Index 146 ZFV-C User’s Manual Section 6 APPENDIX Troubleshooting 117
Section 6 Troubleshooting Troubleshooting This section describes countermeasures for temporary hardware problems. Check the malfunction in this section before sending the hardware for repair. Problem Probable cause and possible countermeasure Page OUTPUT indicator does not lit. • Check the setting of [SYS2]-[OUTPUT]-[ONSTATUS]. To lit the indicator (OUTPUT signal ON) when the judgment is OK, select [OK ON], and to lit the indicator (OUTPUT signal ON) when the judgment is NG, select [NG ON]. p.
Section 6 Error Messages and Corrective Actions Error Messages and Corrective Actions Error Message Cause Countermeasure Page The Sensor Head is not connected correctly. Make sure that the Sensor Head is connected correctly. p.51 NEIGHBOR UNIT IS NOT CONNECT The Amplifier Units are not coupled correctly. Make sure that the Amplifier Units are connected correctly. p.36 SYSTEM ERROR Failed to configure FPGA. Faulty Amplifier Unit Contact your Failed to initialize LCD. OMRON representative.
Section 6 Q&A Q&A Question Can I turn LED light emission of the Sensor Head OFF? Answer Yes, you can. Set [CUSTM]-[LIGHT] to [0000]. p.92 What should I do to set the measurement time as short as possible? There are two ways of setting a shorter measurement time: • Set [SYS1]-[SPEED] to [MAX]. However, measurable screen range will be narrowed. p.96 • Switch the screen display during measurement to “Display only image”. The measurement time can be reduced proportionate to the reduction in display time. p.
Section 6 Specifications and External Dimensions Specifications and External Dimensions Sensor Head ZFV-SC10 (Narrow View) (Unit: mm) 1/4-20UNC Depth 6 33.6 34 20 18.7 34 2-M4 Depth 6 30.1 Mounting hole dimensions 20 ± 0.1 2-M4 67.9 32 4.5 4.5 0.8 5.6 33 Focus adjustment control 17.9 30 6.36 4 8.5 33.6 6.36 12.8 23.3 ZFV-C User’s Manual Section 6 APPENDIX 4.5 4.5 32 Heat-resistant PVC shielded cable 5.
Section 6 Specifications and External Dimensions ZFV-SC50/SC50W (Standard View) (Unit: mm) 34 20 34 1/4-20UNC Depth 6 30.1 38.9 26.5 2-M4 Depth 6 34 20 ± 0.1 A fixing jig can be mounted to each side 2-M4 Mounting hole dimensions 35.2 86 Section 6 APPENDIX 122 ZFV-C User’s Manual 8.5 3 8 6.2 52.5 39 9.8 30.3 6.36 Heat-resistant PVC shielded cable 6.2 Standard 2 m 6.36 5.6 26.5 35.5 5 52.
Section 6 Specifications and External Dimensions ZFV-SC90/SC90W (Wide View) (Unit: mm) 33 1/4-20UNC Depth 6 34 20 30.1 38.9 34 2-M4 Depth 6 33 20 ± 0.1 4 M 2- Mounting hole dimensions 83.7 35.5 33 5.6 30.25 52.5 A mounting bracket can be mounted to each side 8.5 8.5 52.5 39 35.5 4 6.2 9.8 8.5 7 Heat-resistant PVC shielded cable 6.
Section 6 Specifications and External Dimensions ZFV-SC150/SC150W (Ultra Wide View) (Unit: mm) 110.2 59.5 140 29 12 35 57 98 2-M4 20 ± 0.1 Mounting hole dimensions Section 6 APPENDIX 124 ZFV-C User’s Manual Heat-resistant PVC shielded cable 6.2 Standard length 2 m Mounting surface 8.5 8.5 73.2 140 4 8.5 5 7 8.
Section 6 Specifications and External Dimensions Item ZFV-SC10 (Narrow View) ZFV-SC50/SC50W (Standard View) ZFV-SC90/SC90W (Wide View) ZFV-SC150/SC150W (Ultra Wide View) Setting distance (L) 34 to 49 mm (variable) 31 mm to187 mm (variable) 67 to 142 mm (variable) 115 mm to 227 mm (variable) Detection range (H×V) 5 mm × 4.6 mm to 9 mm × 8.3 mm Detection (V) (Variable) range 10 mm × 9.
Section 6 Specifications and External Dimensions Amplifier Unit ZFV-CA40/CA45 52.5 4.61 23.2 (Unit: mm) 90 60 4.3 3.9 10.8 Section 6 APPENDIX 11 .7 24.2 18 32.9 13 10 Item ZFV-CA45 NPN open-collector, 30 VDC, 50 mA max., Residual voltage: 1.2 V max. PNP open-collector, 50 mA max., Residual voltage: 1.2 V max. Input specifications ON Short-circuited with 0 V terminal or 1.5 V or less Supply voltage short-circuited or within supply voltage -1.5 V max. OFF Open (leakage current: 0.
Section 6 Specifications and External Dimensions Item ZFV-CA40 ZFV-CA45 Input signals (1) Simultaneous measurement input (TRIG)/ Continuous measurement input (TRIG) switched by menu. (2) Bank selection inputs (BANK1-3) (3) Workpiece still teaching (TEACH)/Workpiece moving teaching (TEACH) Switched by menu Sensor Head interface Digital interface Image display 1.
Section 6 Specifications and External Dimensions Panel Mount Adapters ZS-XPM1/XPM2 When mounting on a panel (60 × n) + 12 60 × n (Unit: mm) 13 3 Panel (140) 90 122 DIN Track Panel Panel Mount Adapters (2) (37.5) (Note 1) Note 1: Dimensions when the panel thickness is 2.
Section 6 Specifications and External Dimensions Control Link Unit ZS-XCN (Unit: mm) 13.4 11.5 18 Item 4.6 ZS-XCN Ambient temperature Operating: 0 to +50 °C, Storage: -15 to +60 °C (with no icing or condensation) Ambient humidity Operating and storage: 35 % to 85 % (with no condensation) Vibration resistance (destructive) 10 to 150 Hz, 0.7 mm double amplitude, 80 min each in X, Y, and Z directions Section 6 APPENDIX 39.
Section 6 Specifications and External Dimensions Extension Cord ZFV-XC_B(R)V2 (Unit: mm) L (Note 1) 75 13 33 8.5 28 30 36 45.9 2- 3.5 20 pins Mounting hole 20 pins 28±0.1 2-M3 Round PVC insulated cable 6.
Section 6 Specifications and External Dimensions RS-232C Cable ZS-XPT2 (for connecting a programmable controller) (Unit: mm) 2000±150 32.2 (20±5) 41 32.2 24.99 (4) 20 17.6 11.15 5.2 10-pin square connector 8.7 9-pin square connector Note 1 15 Round vinyl insulated cable 3.89 (Conductor cross-sectional area: 0.013 mm2 / Insulator diameter: 0.38) Note 1: Plug type connector ZS-XRS2 (for connecting a personal computer) (Unit: mm) 2000±150 41 32.2 24.99 32.2 11.15 17.
Section 6 Specifications and External Dimensions Lighting Unit (Option) ZFV-LTL01 (bar lighting) (Unit: mm) 20 62 2 × 3-M3 Depth 5 P5.8 × 9 = 52.2 2000 8 ± 0.1 14 8 29 +100 0 37.4 10.7 20 ± 0.1 Mounting hole dimensions 20 69 ± 0.1 2-M3 Depth 5 69 74 Mounting hole dimensions ZFV-LTL02 (bar double-lighting) Section 6 APPENDIX (Unit: mm) 33 4-M4 (Thru) 140 20 350 +35 0 100 140 165.4 85 85 20 20 P5.8 × 9 = 52.2 62 20 100 20 2000+100 0 100 ± 0.1 100 ± 0.
Section 6 Specifications and External Dimensions ZFV-LTL04 (bar low-angle lighting) (Unit: mm) 4-M4(Thru) 165.4 140 33 3.2 62 100 85 P5.8 × 9 = 52.2 20 140 85 165.4 59.9 350 +35 0 20 90° 20 20 100 20 0 2000+100 100 ± 0.1 ZFV-LTF01 (light source for through-beam lighting) (Unit: mm) 1 103 70 22 74 74 0 0 2000 +10 70 (Emitting surface) 109 (Emitting surface) Section 6 APPENDIX 100 ± 0.1 Mounting hole dimensions 4-M3 Depth 8 74 ± 0.1 74 ± 0.
Section 6 Specifications and External Dimensions Item Applicable sensor head ZFV-LTF01 Pulse lighting Lighting interval Fixed (1.1 to 1.4 ms) ZFV-LTL04 White LEDs 60 Section 6 APPENDIX 134 ZFV-LTL02 ZFV-SC50/SC50W/SC90/SC90W Lighting method Light source (Qty.) ZFV-LTL01 20 Power supply voltage 48 VDC (Supplied from sensor head) Current consumption Approx. 160 mA Approx. 80 mA 40 80 Approx. 120 mA Approx.
Section 6 LED Safety Precautions for Using Laser Equipment LED Safety Precautions for Using Laser Equipment For LED devices, class classification to indicate dangerous level and safety standards are stipulated in respective countries. Take necessary safety preventive measures according to the standards.
Section 6 Requirements from Regulations and Standards Requirements from Regulations and Standards Summary of Requirements to Manufactures ■ For Europe EN 60825-1 “Safety of Laser Products, Equipment Classification, Requirements and User’s Guide” Summary of Manufacturer’s Requirements Requirements subclause Description of hazard class Classification Class 1 Class 1M Class 2 Class 2M Class 3R Class 3B Class 4 Safe under reasonably foreseeable conditions As for Class 1 except may be hazardous if user
Section 6 Requirements from Regulations and Standards Requirements subclause Classification Class 1 Class 1M Class 2 Class 2M Class 3R Class 3B Class 4 Wavelength range label Required for certain wavelength ranges LED label Make required word substitutions for LED products User information Operation manuals must contain instructions for safe use.
Section 6 Requirements from Regulations and Standards Summary of Requirements to User ■ For Europe EN 60825-1 Requirements subclause Laser safety officer Remote interlock Key control Beam attenuator Emission indicator device Section 6 APPENDIX Warning signs Beam path Specular reflection Eye protection Protective clothing Training Classification Class 2M Class 3R Class 3B Class 4 Not required for visible Not required but recommended for applications that emission Required involve direct viewing o
Section 6 Requirements from Regulations and Standards Definitions of Laser Classification ■ For Europe Laser Product Classifications EN Class Description Class 1 Lasers which are safe under reasonably foreseeable conditions of operation. Class 2 Lasers emitting visible radiation in the wavelength range from 400 nm to 700 nm. Eye protection is normally afforded by aversion responses including the blink reflex. Class 3A Lasers which are safe for viewing with the unaided eye.
Section 6 Updating the Firmware Updating the Firmware This section describes how to update the firmware of the ZFV-C Series Amplifier Unit. Warp Engine ZS is used to update the firmware. For the file for updating, please contact your OMRON representative. • Never turn OFF the power to the Amplifier Unit during update. Doing so will disable the Amplifier Unit’s ability to start up correctly.
Section 6 Updating the Firmware Connecting the amplifier unit Personal Computer 1. Connect the Amplifier Unit to the personal Computer with a USB cable. When connecting the Amplifier Unit to a Personal computer for the first time, the USB driver must be installed in advance. Setting USB/RS-232C Specifications p.102 2. Communication Turn ON the power supply to the Amplifier Unit. • Make sure that power is supplied to the Amplifier Unit.
Section 6 Updating the Firmware Setting the Firmware Information 4. Click the [Controller information] button if necessary. The model and version number of the currently connected Amplifier Unit will be displayed. 5. Click the [Loading file] button to select the file to be written. The Amplifier Unit model and version number registered in the file will be displayed. Performing Firmware Update 6. Click the [Start upgrade] button in the Section 6 APPENDIX [WarpEngineZS] window.
Section 6 Updating the Firmware 7. Check the message and click the [OK] button. Firmware update will start. Progress of processing will appear during update. Wait until a message informing completion of update appears (update takes a couple of minutes). • An error may occur with the Amplifier Unit during update, but ignore it. • If the update progress bar stops or update is not completed within 10 minutes, there is a possibility that update has failed.
Section 6 Updating the Firmware ■ Setting the connection port If you have failed to start Warp Engine ZS, a message will appear, followed by the dialog box shown on the right. 1. Select [Settings]-[Control Panel] from the [Start] menu of the personal computer, and then double-click [System]. The [System Properties] dialog box will appear. 2. Open the [Hardware] tab and click [Device Manager]. The [Device Manager] dialog box will appear. Section 6 APPENDIX 3.
Section 6 Version upgrade information Version upgrade information Software version upgrade contents are explained. ■ Ver1.00 → Ver1.10 Changes Addition of [COL JUGE] for pattern inspection Page p.65 Addition of horizontal direction ([DIRECTION] ← → ) for width, position and count inspection p.74, p.77, p.80 Addition of workpiece stop teaching function p.97 Addition of still image teaching function p.98 ■ Ver1.10 → Ver1.20 Changes Page Addition of [AREA3] for area inspection p.
Section 6 Index Index A D ADJ mode 27 Adjusting lighting 92 ALL CLEAR 100 Amplifier Unit Installation 32 Restrictions on gang-mounting 116 Specifications and External Dimensions 126 Amplifier unit expansion 22 Amplifier unit gang-mount 110 Area inspection 66 Area value 63, 68 Density average value 82 Density deviation value 82 Density distribution value 86 Detection range 47, 125 DIRECTION 74, 77, 80, 89 DISP COL 97 DISP POS 93 E ECO MODE 98 Edge level 73, 76, 79 EDGE MODE 74, 77, 80, 89 Edge position 7
Section 6 Index Detecting Presence of Character String (CHARA) Hue Pattern Position Installation procedure DIN Track Gang Panel 84 70 62 75 Output cable OUTPUT TIME P Part Names Amplifier Unit Sensor Head Partial function Pattern Inspection Position check Power Supply 32 36 34 K Key Operations MENU/ADJ mode RUN Mode 60 60 57 LANGUAGE LIGHT TEACH Lighting Unit (Option) Lock Function 101 65 132 105 ROTATION RS-232C Cable external dimensions Cable wiring Communication Setting RUN Mode 87 97 54 96 54
Section 6 Index Workpiece move teaching 44 Workpiece stop teaching 43 Threshold AREA 68 AREA1 68 AREA2 68 BRIGHT 82 COUNT 79 HUE 71 Match 63 Pattern 63 POSITION 76 Search 63 WIDTH 73, 86 Timing Charts Synchronous measurement 42 Continuous measurement 42 TRIG 111 U Ultra Wide View USB Communication Setting 125 VERSION 101 Warp Engine ZS WHITE BAL Wide View Width Inspection Wiring 140 100 125 72 39 102 V Section 6 APPENDIX 148 W ZFV-C User’s Manual
Section 7 APPLICATION AND SETTING Inspecting for the Presence of Electronic Components (Pattern) 150 Detecting Mixed Varieties of Campaign Seals (Area) 152 Inspecting Entry of Workpieces of Wrong Color (HUE) 156 Explanation of Color Related Functions 158 Section 7 APPLICATION AND SETTING ZFV-C User’s Manual 149
Section 7 Inspecting for the Presence of Electronic Components (Pattern) Inspecting for the Presence of Electronic Components (Pattern) SEARCH OK OK ABCDE E D C A B NG judgment will also be made if the workpiece contained in a case is placed upside down. C B ABCDE NG A SEARCH If the workpiece is placed upside down, NG judgment will be made since “ ” is not detected inside the teaching area. B NG A SEARCH C D E Adjusting the Camera 1.
Section 7 Inspecting for the Presence of Electronic Components (Pattern) Adjusting the Inspection Area 6. Select [REG.] and press the SET Key. TEACH/SEARCH ITEM 7. Adjust the size of the inspection area and press the SET Key. Enlarge/reduce the window’s green frame so that the inspection area is slightly larger than than the workpiece. 8. Zooms in/out in vertical direction. Move the green frame so that the target is centered in the inspection area. TEACH/REG. Zooms in/out horizontal direction.
Section 7 Detecting Mixed Varieties of Campaign Seals (Area) Detecting Mixed Varieties of Campaign Seals (Area) AREA2 OK OK 1 point AREA2 NG 1 point AREA2 NG 1 point NG because the area of the background color differs from the reference area NG because the area of the “1 Point” color differs from the reference area 1 point 1 point 1 point Adjusting the Camera 1. Adjust the camera so that the workpiece is displayed on the monitor. Adjusting the Sensor Head Focus p.
Section 7 Detecting Mixed Varieties of Campaign Seals (Area) Adjusting the Inspection Area 6. Select [REG.] and press the SET Key. TEACH/AREA2 1 point ITEM 7. Adjust the size of the inspection area and press the SET Key. Enlarge/reduce the screen’s green frame so that the inspection area is slightly larger than than the workpiece. 8. Zooms in/out in vertical direction. Zooms in/out horizontal direction. Move the green frame so that the target is centered in the inspection area. TEACH/REG.
Section 7 Detecting Mixed Varieties of Campaign Seals (Area) 12. Adjust the position of the color pickup area and press the SET Key. TEACH/PICK Vertical direction Horizontal direction 1 point MOVE 13. Select [PICKUP] and press the SET Key. TEACH/PICK Up to four colors are picked up automatically. 1 point SEL 14. If there are colors that are not to be :CHG D :HIST TEACH/PICK selected, use the ↓ key to add a “x” mark. ← → Left/Right Keys: Move to left/right.
Section 7 Detecting Mixed Varieties of Campaign Seals (Area) 19. Check the measurement results displayed AREA2 OK on the LCD monitor.
Section 7 Inspecting Entry of Workpieces of Wrong Color (HUE) Inspecting Entry of Workpieces of Wrong Color (HUE) HUE OK HUE NG OK NG due to wrong color Adjusting the Camera 1. Adjust the camera so that the workpiece is displayed on the monitor. Adjusting the Sensor Head Focus p.49 Setting the Inspection Method Section 7 APPLICATION AND SETTING 2. Select 3. Select [ITEM] and press the SET Key. and press the SET Key. MENU TEACH/SEARCH ITEM 4. Select and press the SET Key.
Section 7 Inspecting Entry of Workpieces of Wrong Color (HUE) Adjusting the Inspection Area 5. Select [REG.] and press the SET Key. TEACH/HUE ITEM 6. Adjust the size of the inspection area and press the SET Key. Zooms in/out in vertical direction. REG. TEACH/REG. Zooms in/out horizontal direction. SIZE 7. Adjust the position of the inspection area and press the SET Key. Move the green frame so that the target is centered in the inspection area. TEACH/REG.
Section 7 Explanation of Color Related Functions Explanation of Color Related Functions Color Pickup Function Up to four candidate colors (colors of the four largest areas) are picked up by simply enclosing the area to be measured. TEACH/PICK Color pickup area Candidate color SEL :CHG D :HIST ■ To check color pickup state Pickup state of candidate colors can be viewed in histogram in the color pickup window.
Section 7 Explanation of Color Related Functions ■ When there are four or more inspection target colors Adjustment of the target color range is possible. In this example, orange color can also be a target if the upper limit is raised. TEACH/PICK H L[ 5] H[ 40] Upper limit Hue Indication Number For color inspection threshold values and upper/limit values (in the color pickup histogram screen), color range must be specified using hue indication numbers.
Section 7 Revision History Revision History A manual revision code appears as a suffix to the catalog number at the bottom of the front and back covers of this manual. Cat. No. Z240-E2-03 Revision code Revision code Date 01 2005. December 02 2006. February • Functions added as per software version upgrade (Ver1.20) • Addition of information for optional lighting unit • Corrections 03 2006. April • Functions added as per software version upgrade (Ver1.
