OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always
heed the information prov ided w ith them . Failure to heed precau tions c an resul t in injury to people
or damage to property.
!DANGERIndicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
!CautionIndicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it
refers to an OMRON product, regardless of whether or not it appears in the proper name of the
product.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types
of information.
NoteIndicates information of particular interest for efficient and convenient opera-
PrecautionIndicates information required to take full advantage of the functions and per-
formance of the product. Incorrect application methods may result in the loss
of damage or damage to the product. Read and follow all precautionary information.
CHECKIndicates points that are important in using product functions or in application
procedures.
TwoCameraIndicates information required when using a 2-camera system.
SeeAlsoIndicates where to find related information.
HELPIndicates information helpful in operation, such as the definition of terms.
¸ OMRON, 2001
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise,
without the prior written permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover,
because OMRON is constantly striving to improve its high-quality products, the information contained
in this manual is subject to change without notice. Every preca ution has been taken in the prepa ration
of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is
any liability assumed for damages resulting from the use of the information contained in this publication.
This manual describes the hardware for the F250 Vision Sensor and how to install the components, and it includes the sections described below. This is one of two manuals used to
operate the F250. Refer to the following table for the contents of each manual.
ManualContentsCat. No.
1:Setup ManualProvides information on system hardware and installa-
2:Operation Manual
(on CD-ROM)
Please read the above manuals carefully and be sure you understand the information provided before attempting to install or operate the F250.
Section 1 Introduction describes the precautions that must be taken when installing and
operating the F250 Vision Sensor.
Section 2 Special Features, Installation, and Connections shows a basic F250 system
configuration and explains how to install the F250 and connect it to a power supply and
peripheral devices.
Section 3 Lenses, Lighting, and Memory Cards describes how to select and use these
components most effectively.
Section 4 Connecting External Devices describes how to connect external devices
through a parallel interface (the parallel connectors) or serial interface (the RS-232C/RS422 connector or Ethernet connector).
Section 5 Troubleshooting and Maintenance provides tables to help identify and correct
hardware errors that may occur with the F250 as well as information on maintenance and
periodic inspections.
tion. Be sure to read this manual first.
The Operation Manual CD-ROM is packed with the
F250-UME Application Software. This manual explains
basic operations such as installing the Application Software, setting up inspection processes, and communicating with external devices.
SCHB-736A
Z153-E1-01
!WARNING Failure to read and understand the information provided in this manual may result in per-
sonal injury or death, damage to the product, or product failure. Please read each section in
its entirety and be sure you understand the information provided in the section and related
sections before attempting any of the procedures or operations given.
ix
PRECAUTIONS
This section provides general precautions for using the F250 Vision Sensor.
The information contained in this section is important for the safe and reliable application of the F250
Vision Sensor. You must read thi s secti on and unde rstand the info rmat ion conta ined bef o r e attempti ng to
set up or operate an F250 Vision Sensor.
When the F250 will be used in one of the conditions or applications listed
below, allow extra safety margins in ratings and f unc tio ns, add e xt r a s afety f ea tures such as fail-safe systems, and consult your OMRON representative.
• Operating conditions or environments which are not described in the
manual
• Nuclear power control systems, railroad systems, aviation systems, vehicles, combustion systems, medical equipment, amusement equipment, or
safety equipment
• Other systems, machines, and equipment that may have a serious influence on lives and property and require extra safety features
2General Safety Precautions
Battery Precautions
!WARNING Do not disassemble the F250, apply pressure to the F250 that would deform
its shape, or incinerate the F250. A lithium battery is built into the F250 and it
may combust, explode, or burn if not treated properly.
!WARNING Do not short circuit, attempt to charge , di sa ssemb le , apply pre ssure t hat w ould
deform, or incinerate the lithium battery. The lithium battery may start a fire,
explode, or burn if not treated properly.
Installation Environment Precautions
!Caution Do not use the F250 in environments with flammable or explosive gases.
!Caution Install the F250 away from high-voltage devices and moving machinery to
allow safe access during operation and maintenance.
!Caution Install the F 250 so that air can flow free ly thro ugh its co oling vents. If the vents
are blocked, heat will build up in the Controller and may cause burns.
Intake vent
!Caution Be sure to securely tighten the screws when mounting the F250.
Power Supply and Wiring Precautions
!Caution Use the F250 with the power supply voltages specified in this manual.
!Caution Use the wire and crimp terminals of the proper sizes as specified in this man-
ual. Do not connect the power supply wires by just twisting stranded wire and
connecting directly to the terminals.
Exhaust vent
xii
!Caution Use a DC power supply with countermeasures against high-voltage spikes
(safe extra low-voltage circuits on the secondary side).
Regulations and Standards3
Note
1.Ke ep t he po wer supply wires as short as possible (Max. 10 m).
2.Ground the F250’s ground terminal to less than 100 W.
3.Use a grounding point as close as possible to the F250 and keep the
ground line as short as possible.
4.Wire the F250 to the groun d with a separ ate gr ound wire . To avoid gro unding problems, do not share the ground wiring with any other devices or
ground the F250 to the building’s steel framing/plumbing.
Other Precautions
!Caution Do not attempt to dismantle, repair, or modify the F250.
!Caution Do not touch fluorescent or halogen lights while the power is ON or immedi-
ately after the power is tur ned OFF. These lights get very hot and can caus e
burns.
!Caution If you suspect an error or malfunction, stop using the F250 immediately, tur n
OFF the power supply, and consult your OMRON representative.
Note Dispose of the F250 as industrial waste.
3Regulations and Standards
The F250 complies with the EC Directive and EN standard below.
1.EC Directives
EMC Directive: No. 89/336/EEC
2.EN Standards (European Standards)
EN 61326: 1997/Annex A+A1: 1998 (EMI: Class A)
xiii
SECTION 1
Introduction
This section describes the p re cau tions th a t must b e t aken when installing and oper atin g th e F2 50 Vision Sensor.
The F250 is highly reliable and resistant to most environmental factors. The
following guidelines, however, must be followed to ensure reliability and optimum use of the F250.
!Caution Read the Precautions section before proceeding with installation or operation.
1-1-1Controller Installation
Installation Site
Do not install the F250 in locations subject to the following conditions:
1,2,3...1.Ambient temperatures outside of the 0 to 50C (32 to 122F) range
2.Rapid temperature fluctuations (likely to cause condensation)
3.Relative humidities outside of the 35% to 85% range
4.Presence of corrosive or flammable gases
5.Presence o f dust, salt, or iron particles
6.Direct vibration or shock
7.Direct sunlight
8.Wa ter, oil, or chemical fumes or spray
Orientation of Controller
To improve heat dissipation, install the Controller in the following orientation
only. For proper air flow, provide at least 20 mm of clearance above the Controller and at least 50 mm of clearance on both sides.
• Horizontal Installation
CORRECT
Do not install the Controller upside down as shown in the following diagram.
INCORRECT
2
Installation PrecautionsSection 1-1
• Vertical Installation
The Controller can be installed vertically with the air intake at the bottom
and exhaust at the top . F or proper air flo w , pro vide at least 20 mm of cle arance at the top of the Controller and at least 50 mm of clearance on both
sides (the intake and exhaust sides).
CORRECT
INCORRECT
Ambient Temperatu re
1,2,3...1.For proper air flow, maintain a minimum clearance of 20 mm at the top of
Exhaust
Intake
Intake
Exhaust
the F250 and at least 50 mm of clearance at the sides where the cooling
air intake and exhaust are located.
2.Do not install the F250 immediately above significant heat sources, such
as heaters, transformers, or large-capacity resistors.
3.Do not let the ambient operating temperature exceed 50C (122F).
4.Provide a forced-air fan cooling or air conditioning if the ambient temperature is near 50C (122F) so that the ambient temperature never exceeds
50C (122F).
Louver
Control panel
F250
3
Installation PrecautionsSection 1-1
Noise Resistance
Use the following measures to help increase noise resistance.
1,2,3...1.Do not install the F250 in a cabinet containing high-voltage equipment.
2.Do not install the F250 within 200 mm of power cables.
Power lines
200 mm min.
200 mm min.
F250
1-1-2Component Installation and Handling
OMRON Components
Use a Camera, Camera Cable, and Console designed specifically for the
F250.
Connecting Cables
Always turn OFF the F250’s power before connecting or disconnecting a camera or cable.
Handling the Camera
The Camera’s case is c onn ec ted to th e 0 V li ne in th e i nte rnal circ ui ts. Observe
the following precautions to prevent noise interference.
1,2,3...1.Do not ground the Camera.
2.Do not remove the base attached to the Camera.
3.Do not remove the ferr it e co re at t ac h ed t o th e F15 0 - VS or F 1 60 -V SR
Camera Cable.
Securing the Video Monitor (When Using the Recommended F150-M09)
Observe the following precautions to prevent noise interference, because the
video monitor case is connected to the 0V line in the internal circuits.
1,2,3...1.Do not ground the video monitor.
2.Do not ground the metallic part of the connector.
3.Secure the video m onitor with plastic scre ws if i t is bei ng moun ted to a metallic surf ac e .
Touching Signal Lines
To prevent damage from static electricity, use a wrist strap or another device
for preventing electrostatic discharges when touching terminals or signal lines
in connectors.
Handling the Memory Card
• To prevent damage from static electricity, do not touch the Memory Card
directly while it is installed in the F250.
• To remove a Memory Card, turn OFF the power supply to the Card (using
the menu command) or turn OFF the F250. Press the eject button to eject
the Card. The Memory Card or t he F250 itself ma y be da ma ged if a M em ory Card is removed while power is being supplied.
Note F250-UME Precautions
It will not be possible to start the Setup Menu if you change the contents of the
Memory Card after installing it in a personal computer or other device. Never
@@
4
Installation PrecautionsSection 1-1
change the contents of the Card with operations such as the following:
• Changing file names
• Moving or deleting files
• Overwriting data
• Formatting
Turning OFF the Power
Do not turn OFF the power while a message is being displayed indicating that
processing is being performed. Data in memory will be corrupted, and the
F250 may not operate correctly the next time it is started.
0.Scn 0 MON
Saving data.
Using the RESET Signal
Do not use the RESET input immediately after power is turned ON. When
using the RESET input to synchronize startup timing, wait at least 1 second
after the F250's power supply is turned ON before turning ON the RESET signal.
---- ---ms
Replacing the Battery
The F250 is equipped with a ba ttery that backs up the clock . Whe n the batte ry
is low, the message “BATTERY LOW” will be displayed on the monitor at startup. The battery must be replaced when this message is displayed. Return the
F250 to your OMRON dea ler for service. (The battery is not user-serviceable.)
The battery will last approximately 7 years.
5
Confirming Package ContentsSection 1-2
1-2Confirming Package Contents
Check the contents of the package as soon as you receive the F250. It is
extremely rare for components to be missing, but contact the nearest OMRON
representative if any of the following items are missing.
1,2,3...1.F250 Vision Mate ControllerQty.: 1
2.Ferrite core for F150-KP Console or F160-KP Console Qty: 1
Ferrite core for F150-VM Monitor CableQty: 1
3.Setup Manual (this manual)Qty.: 1
CHECKThe F250 Vision Sensor Manual 2: Op eration Manual (on CD -R O M) is packed
with the F250-UME Application Software.
1-3Product Availability
Some of the products listed may not be available in some countries. Please
contact your nearest OMRON sales office by referring to the addresses provided at the back of this manual.
6
SECTION 2
Special Features, Installation, and Connections
This section de scribes some of th e speci al featu res of the F25 0, shows a basic F250 system co nfiguratio n, and
explains how to install and wire the F250.
The F250 Vision Sensor uses a camera instead of the human eye to process
images and inspect products. Visual inspections can be automated to perform
complicated inspections quickly and accurately.
There were problematic cases in which Vision Sensors could not detect differences that could be detected by the human eye. The F250 is a high-performance Vision Sensor that solves many of these problems.
8
Special FeaturesSection 2-1
2-1-1Problems Solved with a New Algorithm
EC Defect Inspection
Detect minute damage,
dirt, or deformation!
Dirt on a
Good
Chipped
Quest Optical Character Verification
deformed ring
Verify e xpiration data and
lot number!
Detect incorrect font size/
style as well as errors.
Good
01.01.28
It is possible to inspect for different font styles and sizes.
Size
Width
Interrupted
01.01.28
01.01.28
01.01.28
Italic
Blurred
Bold
01.01.28
01.01.28
01.01.28
9
Special FeaturesSection 2-1
EC Positioning
Very precise positioning
and positioning of lowcontrast objects.
Positioning mark
Low contrast
Inspect for blurred
characters or graphics!
Find differences from the
model image.
Model imageMeasured image
Internal defect
Fine matching
Dirt on design
Chip on edge
10
Minute di rt
Omission
The F250 has many other inspection processes in its line-up.
Special FeaturesSection 2-1
2-1-2Simple and Flexible Inspection Settings
First, install the required inspection processes from the Application Software
Memory Card.
F250-UME Application Software
Processes in the menu can be combined freely.
0.Scn 0=SET=
0.Camera image
1.EC pos. comp
2.Fine matching
3.Binary defect
4.DO data
5.
ENT:Set SFT+ESC:Edit
2-1-3Smooth Switching between Processes
The scene function can be used to set up to 32 diff e rent inspecti ons . When th e
inspection requirements change, the inspection process can be changed just
by changing the scene. Up to 1,024 scenes can be stored on a 128-MB Memory Card.
11
Basic System ConfigurationSection 2-2
2-2Basic System Configuration
The following diagram shows the basic F250 system configuration.
PrecautionSome of the components shown in the configuration diagram are special
OMRON products that ca nnot be s ubst it uted with com parable d evices. T hes e
items are indicated with an asterisk.
Monitor
Monitor with
S-VIDEO input
Use the Monitor to check
images and display the
condition-setting menus.
S-VIDEO Input Cable
(Use a standard cable.)
Controller
This is the F250 Controller itself.
The F250 performs the image
processing specified by the user
settings and outputs the
measurement results.
F150-M05L Color
LCD Monitor
(RCA plug input)
F150-M09 Monochrome
CRT Video Monitor
(BNC input)
BNC Jack
(Included with the
F150-VM Monitor
Cable.)
F150-VM Monitor
Cable (2 m)
Console
F160-KP
(2-m cable)
F150-KP
(2-m cable)
Power
Supply
We recommend the
OMRON S82K-10024.
See page 20 for details.
12
*F150-VS Camera
Cable (3 m)
Basic System ConfigurationSection 2-2
*Cameras
The Camera captures images of the
measurement objects. Up to 4 Cameras
can be connected to one F250 Controller.
CHECKIf F150-@@@ or F160-@@@ Cameras are being used, the connected
Cameras must belong to the same series, i.e., they must have the
same model number prefix (F150 or F160).
• Double-speed Cameras
Camera with Intelligent Lightin g
F160-SLC20 (20-mm field of vision)
F160-SLC50 (50-mm field of vision)
• F150 Cameras
Camera with Intelligent Lighting
F150-SLC20 (20-mm field of vision)
F150-SLC50 (50-mm field of vision)
Camera Only
F160-S1
Use the Camera by itself when the field of
vision of the F160-SLC@0 does not match the
size of the measurement object. A standard
CCTV lens and light source will be needed.
Camera with Intelligent Lighting
F150-SL20A (20-mm field of vision)
F150-SL50A (50-mm field of vision)
Camera Only
F150-S1A
Use the Camera by itself when the field of
vision of the F150-SLC@0 does not match the
size of the measurement object. A standard
CCTV lens and light source will be needed.
CHECK
F200-series and F300-series Cameras can also be connected. Up to four
Cameras can be connected, but they must all have the same model number.
Only one Camera can be connected, however, when the F200-S Camera is
used or when a camera with an internal sync mode is used.
Camera type Camera CableMax. number of Cameras
F200-SF160-VSR31 (Connect to camera connector 0.)
F300-SF160-VSR44
F300-S2RF160-VSR3
F300-S3DR
F300-S4R
(The Cameras must have the same model number.)
SeeAlsoRefer to page 68 for details on parameter settings.
13
Component Names and FunctionsSection 2-3
2-3Component Names and Functions
The following diagram shows the F250 Controller’s major components.
1.RS-232C/RS-422 Conn ec tor
Connects the F250 to an external device such as a personal computer or
PLC.
2.Ethernet Connector (10BASE-T)
Connects the F250 to a personal co mputer. (Can be used with F250-UME
Application Software version 1.10 or higher.)
3.Monitor Connector (S-VIDEO Output)
Connects to a monitor with an S-VIDEO input.
4.Monitor Connector (Comp os ite Vide o Output)
Connects to a monitor.
5.Memory Card Slots 0 and 1
Memory Cards such as the Application Software Memory Card can be inserted in these slots.
6.Memory Card Indicators 0 and 1
Lit when power is bei ng supplie d to the corresp onding Mem ory Card. (The
Memory Card must not be inserted or removed when this indicator is lit.)
7.Console Connec tor
Connects the F250 to a Console.
8.ERROR Indicator
Lit when an error has occurred.
9.RUN Indicator
Lit while the F250 is in Run Mode.
10. POWER Indicator
Lit while power is ON.
11. Parallel Connectors 0 and 1
Connect the F250 to external devices such as a sync sensor or PLC.
12. Camera Connectors 0 to 3
Connect to the Cameras.
13. Ground Terminal
Connects to the ground wire.
14. Power Supply Terminals
Connect to the DC power supply.
14
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