Omron FH-1, FZ5-6, FZ5-11, FZ5-L35, FH-3 User Manual

...
Vision Sensor
FH/FZ5 Series
Vision System
User’s Manual
FH-1 FH-1- FH-3 FH-3- FH-L FH-L-
FZ5-6 FZ5-6- FZ5-11 FZ5-11- FZ5-L35 FZ5-L35-
Z365-E1-02

Introduction

Thank you for purchasing the FH/FZ5. This manual provides information regarding functions, performance and operating methods that are required for using the FH/FZ5. When using the FH/FZ5, be sure to observe the following:
• The FH/FZ5 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.
NOTE
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 precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omis sions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.
Trademarks
Sysmac and SYSMAC are trademarks or registered trademarks of OMRON Corporation in Japan and other countries for OMRON factory automation products.
This software is based in part on the work of the Independent JPEG Group.
Microsoft, Windows, Windows Vista, Excel, and Visual Basic are either registered trade-
marks or trademarks of Microsoft Corporation in the United States and other countries.
Intel, Core and Pentium are trademarks of Intel Corporation in the U.S. and/or other
countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany.
ODVA, CIP, CompoNet, DeviceNet, and EtherNet/IP are trademarks of ODVA.
The SD and SDHC logos are trademarks of SD-3C, LLC.
QR Code is a registered trademark of DENSO WAVE INCORPORATED.
MELSEC is a registered trademarks of Mitsubishi Electric Corporation.
Other company names and product names in this document are the trademarks or registered trademarks of their respective companies.
Copyrights
Microsoft product screen shots reprinted with permission from Microsoft Corporation.

Structure of FH/FZ5 Manuals

The following table gives the manual configuration of the FH/FZ5.
Name of Manual Cat. No. Model Proposes Contents
Vision System FH Instruction Sheet
Vision System FH-L Instruction Sheet
Vision System FZ5 Instruction Sheet
Vision System FZ5-L Instruction Sheet
Vision System FH/FZ5 Series User’s Manual
Vision System FH/FZ5 series Hardware Setup Manual
Vision System FH/FZ5 series Macro Customize Functions Programming Manual
Vision System FH/FZ5 series Processing Item Function Reference Manual
Vision System FH/FZ5 Series User’s Manual for Communications Settings
Vision System FH Series Operation Manual for Sysmac Studio
9607479-9
9606631-1
9524422-4
9910002-2
Z365
Z366
Z367
Z341
Z342
Z343
FH-1 FH-1- FH-3 FH-3-
FH-L FH-L-
FZ5-6 FZ5-6- FZ5-11 FZ5-11-
FZ5-L35 FZ5-L35-
FH-1 FH-1- FH-3 FH-3- FH-L FH-L-
FZ5-L35 FZ5-L35- FZ5-6

FZ
5-6- FZ5-11 FZ5-11-
FH-1 FH-1- FH-3 FH-3-
To confirm the safety and usage precautions of the Vision System FH series Sensor Controller.
To confirm the safety and usage precautions of the Vision System FH-Lite series Sensor Controller.
To confirm the setup procedures, safety and usage precautions of the Vision System FZ5 series Sensor Controller, including I/O setup and wiring
To confirm the setup procedures, safety and usage precautions of the Vision System FZ5-L Series Sensor Controller, including I/O setup and wiring.
When User want to know how to setup the Sensor Controller of the Vision System FH/FZ5 series.
When User want to know about the Hard-ware specifications or to setup the Sensor Controller of the Vision System FH/FZ5 series.
When User operate or programming using Macro Customize functions.
When User confirm the details of each processing items at the create the measurement flow or operate it.
When User confirm the setting of communication functions.
When User connect to NJ series via EtherCAT communication.
Describes the definitions of basic terms, meaning of signal words, and precautions for correct use of FH series in the manual.
Describes the definitions of basic terms, meaning of signal words, and precautions for correct use of FH-L series in the manual.
Describes the definitions of basic terms, meaning of signal words, and precautions for correct use of FZ5 series in the manual.
Describes the definitions of basic terms, meaning of signal words, and precautions for correct use of FZ5-L series in the manual.
Describes the soft functions, setup, and operations to use Sensor Controller of the Vision System FH/ FZ5 series.
Describes FH/FZ5 series specifications, dimensions, part names, I/O information, installation information, and wiring information.
Describes the functions, settings, and operations for using Macro Customize function of the FH/FH5­series.
Describes the software functions, settings, and operations for using FH/FH5-series.
Describes the functions, settings, and communications methods for communicating between FH/FH5 series. The following communication protocol are described. Parallel, PLC Link, EtherNet/IP, EtherCAT, and Non-procedure
Describes the operating procedures for setting up and operating FH series Vision Sensors from the Sysmac Studio FH Tools.
Vision System FH/FZ5 Series User’s Manual (Z365)
1

Conventions Used in This Manual

Symbols
The symbols used in this manual have the following meanings.
IMPORTANT
Note
Indicates relevant operational precautions that must be followed.
Indicates operation-related suggestions from OMRON.
Use of Quotation Marks and Brackets
In this manual, menus and other items are indicated as follows.
[ ] Menu Indicates the menu names or processing items shown in the menu bar.
Item name Indicates the item names displayed on the screen.
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User’s Manual (Z365)

Definitions of Basic Terms

Ter m Definition
FH series
All FH series model names as follows: FH-1, FH-1-, FH-3, FH-3-, FH-L, FH-L-
FH-1000 series
FH-3000 series
FH-L series
FZ5 series
FZ5-600 series
FZ5-1100 series
FZ5-L series
measurement flow (a
measurement processing Executing processing items for inspections and measurements.
Measurement ID
processing item
bbrevia
ted as “flow”)
All FH-1 series model names as follows: FH-1, FH-1-
All FH-3 series model names as follows: FH-3, FH-3-
All FH-L series name the following: FH-L, FH-L-
All FZ5 series name shows the following: FZ5-6, FZ5-6-, FZ5-11, FZ5-11-, FZ5-L35, FZ5-L35-
All FZ5-6 series name the following: FZ5-6, FZ5-6-
All FZ5-11 series name the following: FZ5-11, FZ5-11-
All FZ5-L35 series name the following: FZ5-L35, FZ5-L35-
A continuous flow of measurement processing. A measurement flow consists of a scene created from a combination of processing items.
Information of time when the sensor controller receives the measurement trigger and the line no. Format of measurement ID: YYYY-MM-DD_HH-MM-SS-XXXX YYYY: Year (4 digits) MM: Month DD: Date HH: Hour MM: Minute SS: Second XXXX: Millisecond Example: Measured time: 12/24/2007, 11:10:25.500: Line: 0 Measurement ID: 2007-12-24_11-10-25-5000
Any of the individual items for vision inspections that are partitioned and packaged so that they can be flexibly combined. These include the Search, Position Compensation, and Fine Matching items. Processing items can be classified for image input ([Input image]), inspection/measurement ([Measurement]), image correction ([Compensate image]), inspection/measurement support ([Support measurement]), process branching ([Branch]), results external output ([Output result]), resulting image display ([Display result]), etc. You can freely classify processing items to handle a wide range of applications. A scene (i.e., a unit for changing the measurement flow) is created by registering the processing items as units.
A unit for changing the measurement flow that consists of a combination of processing items. “Scene” is used because of the correspondence to the scene (i.e., type of measurement object and inspection contents) where measurements are performed. A scene is created for each measurement or measurement contents.
scene
Vision System FH/FZ5 Series User’s Manual (Z365)
You can easily achieve a changeover simply by changing the scene when the measurement object or inspection content changes. Normally you can set up to 128 scenes. If you need more than 128 scenes, you can separate them into different groups or use the Conversion Scene Group Data Tool to create a scene group that contains over 128 scenes.
3
Ter m Definition
A processing item that is registered in a scene.
processing unit (abbreviated as “unit”)
measurement trigger
test measurement
single measurement A measurement that is executed only once in synchronization with the trigger input.
continuous measurement Measurements are executed repeatedly and automatically without a trigger input.
Double Speed Multi­input
Multi-line Random­trigger
operation modes
Non-stop Adjustment
Standard
parallel processing (an option for any of the above operation modes)
Numbers are assigned to processing units in order from the top and they are executed in that order. Processing items are registered for the processing units to create a scene (i.e., a unit for changing the measurement flow).
A trigger for executing measurements. With a parallel interface, the STEP signal or command 00 (Continuous Measurement) is used. With a serial interface, an Execute One Measurement or a Start Continuous Measurement command is used.
A measurement that is performed to manually test (check) measurements under the conditions that are set in the currently displayed scene. Test measurements can be executed on an Adjustment Window. Processing is completed inside the Controller and the measurement results are not normally output on an external interface. However, you can select [Output] in [Test measurement] to output the measurement results after executing measurements.
A mode that processes the measurement flow for the first trigger and then processes the measurement flow in parallel for the second trigger to achieve a high-speed trigger input interval. It is used together with the multi-input function.
A trigger mode that allows you to independently processing multiple measurement flows. With traditional image processing, two or more triggers cannot be acknowledged at the same time. In Multi-line Random-trigger Mode, you can randomly input multiple triggers into one Controller to independently process multiple scenes in parallel.
A mode that allows you to adjust the flow and set parameters while performing measurements. The enables adjustments without stopping the line or stopping inspections.
A logging mode that allows complete parallel processing of measurements and logging. Traditionally, logging was not possible while processing measurements. Either measurements or logging had to be given priority and the other one had to wait. With this mode, you can save the measurement images in external memory without affecting the transaction time.
Parallel processing splits part of the measurement flow into two or more tasks, and processes each task in parallel to shorten the transaction time. Processing items for parallel processing are used so that the user can specify the required parallel processing.
multi-input function
4
A function that is used to consecutively and quickly input images. It allows the next STEP signal to be acknowledged as soon as the image input processing is completed. There is no need to wait for measurement processing to be completed. You can check whether image input processing has been completed with the status of the READY signal. Even if the READY signal is ON when measurement processing is being executed, the next STEP signal can be acknowledged.
Vision System FH/FZ5 Series
User’s Manual (Z365)
Ter m Definition
When position of object to be measured is deflected
When position deflection correction is set in advance:
Object to be measured overflows Measurement area.
Reference position
Measurement area and objects to be measured are correctly aligned.
Object to be measured
Measurement area
Measurement will be carried out after measured object enters into Measurement area.
Measurement will be carried out after moving the Measurement area for a corresponding deflection.
Measurement will be carried out after moving the image for a corresponding deflection and returning to the reference position.
Position compensation
When the locatio between reference position and current position is calculated and measurement is performed after correcting. Please select processing items that are appropriate to the measurement object from processing items that are related to position compensation.
n and direction of measured objects are not fixed, the positional deviation
Reference position
Model
The point that is always the reference. If the location of the registered model is different from the reference position, the setting should be changed in [Ref. setting].
The image pattern that serves as the inspection target. Characteristics portions are extracted from images of the object and registered as model registration.
Vision System FH/FZ5 Series User’s Manual (Z365)
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Ter m Definition
“1” is expresses with 2’s Complement (for 8 bits)
00000000 (= 0)
)
(In the case of 1, minus 1)
00000001 (= 1)
11111111 (=1)
(
2's complement
Binary numbers are generally used to represent negative numbers. Negative numbers are expressed by "Inverting all bits of a positive number and adding 1 to the result". (Example) "1" is expressed as 2's complement
"1" can be calculated by "0-1".
There are methods for simple calculation without performing this kind of computation. For instance, "Negative number = inverting all bits of a positive number and then adding 1 to the result".
00000001 (= 1)
Invert all bits
11111110
Plus 1
11111111 (=1)
The first digit is used to judge whether the number is positive or negative.
• When 0: Positive number (or 0)
• When 1: Negative number
The advantage of two's complement numbers is that positive and negative numbers can be used as is in calculations. (Example) When −1+10=9
1
1111111 (= 1)
+)00001010 (= 10)
00001001
= 9)
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Vision System FH/FZ5 Series
User’s Manual (Z365)

Contents

Structure of FH/FZ5 Manuals ............................................................................................................... 1
Conventions Used in This Manual ........................................................................................................ 2
Definitions of Basic Terms .................................................................................................................... 3
Terms and Conditions Agreement ...................................................................................................... 13
Safety Precautions .............................................................................................................................. 15
Precautions for Safe Use .................................................................................................................... 17
Precautions for Correct Use ............................................................................................................... 20
Regulations and Standards ................................................................................................................ 23
1. Before Operation ..........................................................................................................................27
Overview .................................................................................................................................................. 28
Basic Mechanism for Measurements .................................................................................................. 28
Support for a Variety of Scenes and Measurement Lines .................................................................. 29
Flow of Application ................................................................................................................................... 31
Windows .................................................................................................................................................. 33
Types of Windows .............................................................................................................................. 33
Overview of Window Navigation ......................................................................................................... 34
Main Window (Layout 0): Adjustment Window (Default) .................................................................... 35
Main Window (Layout 1): Run Window (Default) ................................................................................ 41
Menu List ............................................................................................................................................ 42
Checking the System Configuration ......................................................................................................... 44
System Configuration ......................................................................................................................... 44
Functional Comparison between the FH-series and FZ5-series Controllers ...................................... 45
Saving Settings before Turning OFF the Power and Restarting .............................................................. 49
Restarting the Controller: [System Restart] ........................................................................................ 49
Turning OFF the LCD ......................................................................................................................... 50
Accuracy .................................................................................................................................................. 51
Initializing the Controller ........................................................................................................................... 52
Initializing the Controller: [System initialization] .................................................................................. 52
2. Setting Scenes (Measurement Flows) ........................................................................................53
What Is a Scene? ..................................................................................................................................... 54
Example of a Scene ............................................................................................................................ 55
What Is a Scene Group? .......................................................................................................................... 57
Creating a Scene ..................................................................................................................................... 58
Editing Processing Units in Scenes ......................................................................................................... 59
Displaying and Checking Processing Branches in a Scene .................................................................... 62
Changing the Scene or Scene Group ...................................................................................................... 66
Changing the Scene ........................................................................................................................... 66
Changing Scene Groups .................................................................................................................... 66
Editing Scenes ......................................................................................................................................... 68
Copying Scenes .................................................................................................................................. 68
Deleting Scenes .................................................................................................................................. 68
Renaming a Scene and Adding a Description .................................................................................... 69
Editing Scene Groups .............................................................................................................................. 70
Copying and Deleting Scene Groups ................................................................................................. 70
Changing the Scene Group Name ...................................................................................................... 71
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3. Performing Test Measurement/Starting Operation ...................................................................73
Adjustment Windows and Run Windows ................................................................................................. 74
Main Window (Layout 0): Adjustment Window (Default) .................................................................... 74
Main Window (Layout 1): Run Window (Default) ................................................................................ 75
Main Window (Layout 1): Changing to the Run Window .................................................................... 75
Main Window (Layout 1): Changing to the Adjustment Window ......................................................... 75
Preparing the Controller and Cameras .................................................................................................... 76
Camera Setup ..................................................................................................................................... 76
Preparing a Controller ......................................................................................................................... 78
Adjusting the Camera ......................................................................................................................... 78
Executing Test Measurements ................................................................................................................ 79
Key Points for Adjustment ........................................................................................................................ 80
Stabilizing Measurements ................................................................................................................... 80
Shortening Processing Time ............................................................................................................... 81
Arranging Windows .................................................................................................................................. 83
Arranging Window Elements (Layout Modification) ............................................................................ 83
Setting the Behavior of Output Signals for Each Layout (Layout Settings) ........................................ 98
Changing Layout Numbers in the Main Window ................................................................................. 98
Troubleshooting .................................................................................................................................. 99
Arranging the Window Display ............................................................................................................... 100
Changing the Image Mode and Other Display Contents .................................................................. 100
Custom Dialogs ...................................................................................................................................... 103
Flow of Use ....................................................................................................................................... 103
Custom Dialog Tool .......................................................................................................................... 104
Launching Your Custom Dialog Box ................................................................................................. 115
Useful Functions for Operation .............................................................................................................. 116
Remeasuring Saved Images ............................................................................................................ 116
Improving Adjustment Efficiency ....................................................................................................... 117
Changing Judgement Conditions without Stopping Measurement ................................................... 118
Changing Regions as a Batch [Shift area] ........................................................................................ 119
Monitoring Measurement Value Trends ............................................................................................120
Logging Measurement Values and Measurement Images ............................................................... 120
Analyzing Logged Data ..................................................................................................................... 132
Clearing Measurement Results ........................................................................................................ 134
Clearing Saved Images .................................................................................................................... 134
Capturing Screen Images ................................................................................................................. 134
Checking the Memory Consumption and Percentage of Memory Used ........................................... 136
Using the Operation Log ................................................................................................................... 137
Operation Log Format ....................................................................................................................... 139
Saving Data to an External Device ................................................................................................... 140
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4. Using Tools .................................................................................................................................143
Limiting user operations (Security settings) ........................................................................................... 144
Setting Accounts (Account List) ........................................................................................................ 144
Setting Layout Restrictions ............................................................................................................... 146
Setting User Group Operation Restrictions ......................................................................................147
Saving/Loading/Deleting the Security Settings ................................................................................. 149
Changing between user accounts .......................................................................................................... 155
Logging in ......................................................................................................................................... 155
Logging Out ...................................................................................................................................... 155
Saving Scene groups in external memory (Scene Group Saving Destination settings) ........................ 156
Analyzing inspection and measurement results (NG analyzer) ............................................................. 158
Layout of NG Analyzer Window ........................................................................................................ 159
Using Method of NG Analyzer .......................................................................................................... 160
Sharing data within the controller (User data tool) ................................................................................. 163
Setting Procedure for User Data ....................................................................................................... 163
Outputting a List of Scene Data Set Values (Settings download and upload tools) .............................. 165
Downloading Set Values ................................................................................................................... 165
About Downloaded CSV Files .......................................................................................................... 165
Uploading Set Values ....................................................................................................................... 167
Saving Image files to a RAMDisk, or External memory device (Image file save) .................................. 168
Managing images used for model registration and reference (Registered Image Manager) ................. 170
Registering Images ........................................................................................................................... 170
Loading an Image ............................................................................................................................. 171
Customizing communication commands (Communication command macro) ....................................... 172
Displaying a measurement flow as a flowchart while editing it (Flow viewer) ........................................ 173
Verifying calibration results (Calibration support tool) ............................................................................ 174
Updating the referenced position data for a unit in the measurement flow
(Update standard position tool) .............................................................................................................. 175
Increasing the number of scenes in a group to more than 128 scenes
(Conversion scene group data tool) ....................................................................................................... 177
Create a customized settings dialog box (Custom dialog tool) .............................................................. 180
Extending the functions in a measurement flow, or scene (Scene Control Macro Tool) ....................... 181
Backing up Sensor Controller setting data (Configuration copy) ........................................................... 182
Before backing up ............................................................................................................................. 182
Backing up Sensor Controller settings .............................................................................................. 184
Restoring settings with saved settings data ...................................................................................... 194
Troubleshooting ................................................................................................................................ 197
Changing settings for each line in Multi-line Random-trigger mode (Line Maintenance) ....................... 199
Before use of Line Maintenance ....................................................................................................... 199
Line Maintenance tool operations ..................................................................................................... 202
Operating with Functional Limitations ............................................................................................... 209
Troubleshooting ................................................................................................................................ 213
Remotely operating the controller (Remote Operation) ......................................................................... 214
Overview ........................................................................................................................................... 214
Operation Environment Condition ..................................................................................................... 215
How to Start ...................................................................................................................................... 217
Vision System FH/FZ5 Series User’s Manual (Z365)
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5. Saving Data to the FH series/FZ5 series ..................................................................................221
Saving Data to the FH series/FZ5 series ............................................................................................... 222
About Saving Areas .......................................................................................................................... 222
External Drive Names ....................................................................................................................... 223
Using External Memory Devices (FH series/FZ5-1100 series only) ................................................. 224
Shared folder on a computer connected to the network ................................................................... 224
Saving Settings Data to the Flash Memory and Restarting ................................................................... 225
Saving Settings Data to the Controller RAMDisk or an External Memory Device ................................. 226
Saving Logged Images in the Controller Memory (RAM) to a RAMDisk or
an External Memory Device ................................................................................................................... 227
Copying or Moving Files between the Controller RAMDisk and an External Memory Device ............... 228
Loading Settings Data from the Controller RAMDisk or an External Memory Device to the
Sensor Controller ................................................................................................................................... 229
6. Changing the System Environment .........................................................................................231
Setting the Camera Conditions .............................................................................................................. 232
Checking the Camera Connections: [Camera Connection] .............................................................. 232
Setting the Trigger Delay: [Inter-camera setting] ..............................................................................232
Setting the SHTOUT Signal: [Output Signal Settings] ...................................................................... 235
Setting the Conditions That Are Related to Operation during Measurement ......................................... 237
Setting the Operation Mode ................................................................................................................... 238
Selection Guide for Operation mode ................................................................................................ 239
Double Speed Multi-input ................................................................................................................. 240
Multi-line Random-trigger Mode ....................................................................................................... 244
Non-stop Adjustment Mode .............................................................................................................. 250
Standard (Operation Mode) .............................................................................................................. 252
Parallel Processing ................................................................................................................................ 253
Parallel Processing Settings (Automatic Parallelization) .................................................................. 253
Parallel Processing Settings (Manual Parallelization) ...................................................................... 253
Specific Example of Parallel Processing .......................................................................................... 255
Restrictions ....................................................................................................................................... 256
Setting Procedures ........................................................................................................................... 259
Multi-trigger Imaging Processing Function ............................................................................................. 263
Settings for Multi-trigger Imaging ...................................................................................................... 264
Restrictions ....................................................................................................................................... 266
Setting Methods ................................................................................................................................ 267
About Multi-input function (Multi-trigger Imaging) .............................................................................271
Troubleshooting ................................................................................................................................ 276
Setting the Operating Environment of the System ................................................................................. 277
Selecting Language [Startup Settings] ............................................................................................. 277
Setting the Status at Startup [Startup Settings] ................................................................................ 278
Setting Communication [Startup Settings] ........................................................................................ 280
Setting Operation mode [Startup Settings] ....................................................................................... 284
Date-time setting [Other] ................................................................................................................... 285
Fan control setting [Other] ................................................................................................................ 285
STEP setting [Other] ......................................................................................................................... 286
Encoder trigger setting [Other] .......................................................................................................... 287
Network drive setting [Other] ............................................................................................................ 289
Error Setting [Other] .......................................................................................................................... 291
Checking System Information [System Information] ......................................................................... 293
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7. Appendices ................................................................................................................................297
Alignment ............................................................................................................................................... 298
Overview ........................................................................................................................................... 298
Execution of Calibration .................................................................................................................... 301
Troubleshooting ................................................................................................................................ 308
Alignment .......................................................................................................................................... 309
Alignment Processing Items ............................................................................................................. 316
Error Messages and Troubleshooting .................................................................................................... 317
FAQ ........................................................................................................................................................ 323
During Start-up ................................................................................................................................. 323
During Operation .............................................................................................................................. 324
For Measurement ............................................................................................................................. 325
About Parallel Interface ................................................................................................................... 326
Serial Interface (RS-232C/422 Connection) ..................................................................................... 327
Camera with Lighting Controller ....................................................................................................... 327
Measurement Mechanism ...................................................................................................................... 328
Color Processing Mechanism .......................................................................................................... 328
Search Processing Mechanism ....................................................................................................... 329
Edge Detection Measurement .......................................................................................................... 332
Defect Detection Measurement ........................................................................................................ 335
Handling Coordinates ...................................................................................................................... 336
Basic Knowledge about Operations ....................................................................................................... 337
Inputting Values ............................................................................................................................... 337
Inputting Text ................................................................................................................................... 337
Selecting Files and Folders ............................................................................................................. 338
Available Operations in Select File Window ....................................................................................340
Using the Zoom Function .................................................................................................................. 341
Setting Figures ....................................................................................................................................... 342
Layout of Figure Setting Area .......................................................................................................... 342
Setting Methods ............................................................................................................................... 343
About OR Setting/NOT Setting ......................................................................................................... 349
Image file ............................................................................................................................................... 350
About Number of Logging Images ......................................................................................................... 352
About Limits on the Number of Image Input Processing Items Used .................................................... 355
About Max. Number of Loading Images during Multi-input .................................................................... 356
Character Code Table ............................................................................................................................ 357
About Memories Usable with FH series/FZ5 series ............................................................................... 358
Memory Usage Guidance For Processing Items ................................................................................... 359
Memory Display Image on PLC I/O ....................................................................................................... 364
Operation log input information list ........................................................................................................ 366
Manual Revision History ........................................................................................................................ 379
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Vision System FH/FZ5 Series
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Terms and Conditions Agreement

Warranty, Limitations of Liability
Warranties
Exclusive Warranty
Omron’s exclusive warranty is that the Products will be free from defects in materials and workmanship for a period of twelve months from the date of sale by Omron (or such other period expressed in writing by Omron). Omron disclaims all other warranties, express or implied.
Limitations
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NON­INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCTS. BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. Omron further disclaims all warranties and responsibility of any type for claims or expenses based on infringement by the Products or otherwise of any intellectual property right.
Buyer Remedy
Omron’s sole obligation hereunder shall be, at Omron’s election, to (i) replace (in the form originally shipped with Buyer responsible for labor charges for removal or replacement thereof) the non-complying Product, (ii) repair the non-complying Product, or (iii) repay or credit Buyer an amount equal to the purchase price of the non-complying Product; provided that in no event shall Omron be responsible for warranty, repair, indemnity or any other claims or expenses regarding the Products unless Omron’s analysis confirms that the Products were properly handled, stored, installed and maintained and not subject to contamination, abuse, misuse or inappropriate modification. Return of any Products by Buyer must be approved in writing by Omron before shipment. Omron Companies shall not be liable for the suitability or unsuitability or the results from the use of Products in combination with any electrical or electronic components, circuits, system assemblies or any other materials or substances or environments. Any advice, recommendations or information given orally or in writing, are not to be construed as an amendment or addition to the above warranty.
See http://www.omron.com/global/ or contact your Omron representative for published information.
Limitation on Liability; Etc
OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE OR STRICT LIABILITY.
Further, in no event shall liability of Omron Companies exceed the individual price of the Product on which liability is asserted.
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Application Considerations
Suitability of Use
Omron Companies shall not be responsible for conformity with any standards, codes or regulations which apply to the combination of the Product in the Buyer’s application or use of the Product. At Buyer’s request, Omron will provide applicable third party certification documents identifying ratings and limitations of use which apply to the Product. This information by itself is not sufficient for a complete determination of the suitability of the Product in combination with the end product, machine, system, or other application or use. Buyer shall be solely responsible for determining appropriateness of the particular Product with respect to Buyer’s application, product or system. Buyer shall take application responsibility in all cases.
NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT(S) IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
Programmable Products
Omron Companies shall not be responsible for the user’s programming of a programmable Product, or any consequence thereof.
Disclaimers
Performance Data
Data presented in Omron Company websites, catalogs and other materials is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of Omron’s test conditions, and the user must correlate it to actual application requirements. Actual performance is subject to the Omron’s Warranty and Limitations of Liability.
Change in Specifications
Product specifications and accessories may be changed at any time based on improvements and other reasons. It is our practice to change part numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the Product may be changed without any notice. When in doubt, special part numbers may be assigned to fix or establish key specifications for your application. Please consult with your Omron’s representative at any time to confirm actual specifications of purchased Product.
Errors and Omissions
Information presented by Omron Companies has been checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical or proofreading errors or omissions.
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Vision System FH/FZ5 Series
User’s Manual (Z365)

Safety Precautions

CAUTION
Symbols and the meanings for safety precautions described in this manual.
In order for the product to be used safely, the following indications are used in this book to draw your attention to the cautions. The cautions with the indications describe the important contents for safety.
Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate
WARNING
injury, or may result in serious injury or death. Additionally there may be significant property damage.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or in property damage.
Meanings of Alert Symbols
The following alert symbols are used in this manual.
General Prohibition Indicates general prohibitions, including warnings, for which there is no specific symbol.
General Caution Indicates general cautions, including warnings, for which there is no specific symbol.
Electrical Hazard Indicates the possible danger of electric shock under specific conditions.
Explosion Hazard Indicates the possible danger of explosion under specific conditions.
Laser Radiation Hazard Indicates the possible danger of laser radiation or light.
High Temperature Caution Indicates the possible danger of injury by high temperature under specific conditions.
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Alert statements in this Manual
WARNING
The following alert statements apply to the products in this manual. Each alert statement also appears at the locations needed in this manual to attract your attention.
This product must be used according to this manual or Instruction sheet. Failure to observe this may result in impairment of functions and performance of the product.
This product is not designed or rated for ensuring safety of persons. Do not use it for such purposes.
Never connect the AC power supply with this product. When the AC power supply is connected, it causes the electric shock and a fire.
A lithium battery is built into the Controller and may occasionally combust, explode, or burn if not treated properly. Dispose of the Controller as industrial waste, and never disassemble, apply pressure that would deform, heat to 100°C or higher, or incinerate the Controller.
Since camera that can be connected with this product emits a visible light that may have an adverse effect on the eyes, do not stare directly into the light emitted from the LED. If a specular object is used, take care not to allow reflected light enter your eyes.
Do not touch the terminals while the power supply is ON. Doing so may result in electrical shock.
Please take external safety measures so that the system as a whole should be on the safe side even if a failure of a Sensor Controller or an error due to an external factor occurred. An abnormal operation may result in serious accident.
Please take fail-safe measures on your side in preparation for an abnormal signal due to signal conductor disconnection and/or momentary power interruption. An abnormal operation may result in a serious accident.
CAUTION
Danger of burns. Do not touch the case while the LED is ON or just after power is turned OFF, since it remains extremely hot.
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Vision System FH/FZ5 Series
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Precautions for Safe Use

Condition of the fitness of OMRON products
• Please do not use this product to directly or indirectly use to detect the human body for the purpose of ensuring the safety. In the same application, please use the safety sensor that is published on our sensor catalog.
• Omron products are designed and manufactured as general-purpose products for use in general industrial applications. They are not intended to be used in the following critical applications. If you are using Omron products in the following applications, Omron shall not provide any warranty for such Omron products, unless otherwise specifically agreed or unless the specific applications are intended by Omron. (a) Applications with stringent safety requirements, including but not limited to nuclear power control
equipment, combustion equipment, aerospace equipment, railway equipment, elevator/lift equipment, amusement park equipment, medical equipment, safety devices and other applications that could cause danger/harm to people’s body and life.
(b) Applications that require high reliability, including but not limited to supply systems for gas, water and
electricity, etc., 24 hour continuous operating systems, financial settlement systems and other applications that handle rights and property.
(c) Applications under severe condition or in severe environment, including but not limited to outdoor
equipment, equipment exposed to chemical contamination, equipment exposed to electromagnetic interference and equipment exposed to vibration and shocks
(d) Applications under conditions and environment not described in specifications
*1 In addition to the applications listed from (a) to (d) above, Omron products (see definition) are not intended
for use in vehicles designed human transport (including two wheel vehicles). Please do NOT use Omron products for vehicles designed human transport. Please contact the Omron sales staff for information on our automotive line of products.
*2 The above is part of the Terms and Conditions Agreement. Please use carefully read the contents of the
guarantee and disclaimers described in our latest version of the catalog, data sheets and manuals.
Installation Environment
• Do not use the product in areas where flammable or explosive gases are present.
• Install the product so that air can flow freely through its cooling vents.
• Clean the ventilation holes and fan outlet regularly to prevent dust and particles from clogging them. If they are blocked, heat is trapped inside, causing a malfunction.
• Do not install the product close to high-voltage devices and power devices in order to secure the safety of operation and maintenance.
• Make sure to tighten all installation screws securely.
• When mounting the Sensor Controller using the DIN rail mounting bracket, make sure the screw is tightened.
• Make sure to mount the product on DIN-rail securely.
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Power Supply and Wiring
• Make sure to use the product with the power supply voltage specified by this manual or Instruction sheet.
• Do not connect AC power source to Sensor Controller. If connects AC power source, it might be a cause of the failure.
• Use the wire of a suitable size (AWG 16 to 12) according to the current consumption.
• Use a DC power supply with safety measures against high-voltage spikes (safety extra low-voltage circuits on the secondary side).
• Do the following confirmations again before turning on the power supply.
Is the voltage and polarity of the power supply correct? (24 VDC)
Is not the load of the output signal short-circuited?
Is the load current of the output signal appropriate?
Is not the mistake found in wiring?
Is the voltage and polarity of the encoder power (ENC0_VDD/GND ENC1_VDD/GND) supply? (5 VDC)
• The recommended power supply is the S8VS-24 (manufactured by OMRON) or S8VK-G-24 (manufactured by OMRON).
Ground
• Make sure the power supply circuit of the FH Sensor Controller is insulated from the internal circuit. Refer to this manual or Instruction sheet.
• When the connected camera to Sensor Control comes packaged with a base, make sure to mount with the base. Since the enclosure of the camera main body made of metals is short-circuited with the internal circuit, the internal circuit might be short-circuited with FG if no base is used, so that failures or malfunctions may be caused. Perform Class D grounding (with a grounding resistance of 100 or less). Keep the ground line as short as possible by setting the grounding point as close as possible. Ground the FH Sensor Controller independently. If sharing the ground line with other devices or connecting it with a building beam, the Sensor Controller might be adversely effected.
• Check wiring again before turning on the FH Sensor Controller.
• Do not ground the plus (+) terminal when the FH series Sensor Controller is connected to the FH-SC12/ FH-SM12. Doing so may cause a short circuit of the internal circuit, resulting in a malfunction. The internal circuit is possible to be given damage, it can be cause the failure.
FH-1000 series
FH-3000 series
FH-L series
• Do not ground the plus (+) terminal of the 24VDC power source when the FH series Sensor Controller is connected to the FH-MT12 with a USB cable. Doing so may cause a short circuit of the internal circuit, resulting in a malfunction.
FH-1000 series
FH-3000 series
FH-L series
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Vision System FH/FZ5 Series
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Other
• Use only the camera and cables designed specifically for the product. Use of other products may result in malfunction or damage of the product.
• Always turn OFF the power of the Sensor Controller and peripheral devices before connecting or disconnecting a camera or cable. Connecting the cable with power supplied may result in damage of the camera or peripheral devices.
• For the cable that is flexed repeatedly, use the robotic cable type (Bend resistant camera cable) to prevent damages.
• Do not apply torsion stress to the cable. It may damage the cable.
• Secure the minimum bending radius of the cable. Otherwise the cable may be damaged.
• Do not attempt to dismantle, repair, or modify the product.
• Should you notice any abnormalities, immediately stop use, turn OFF the power supply, and contact your OMRON representative.
• While the power is ON or immediately after the power is turned OFF, the Sensor Controller and camera case are still hot. Do not touch the case.
• When disposing of the product, treat it as an industrial waste.
• Do not drop the product nor apply excessive vibration or shock to the product. Doing so may cause malfunction or burning.
• This product is heavy. Be careful not to drop it while handling.
• A lithium battery is incorporated, so a severe injury may rarely occur due to ignition or explosion.
• Be sure to take fail-safe measures externally when controlling stages and robots by using the measurement results of the Sensor Controller (axis movement output by calibration and alignment measurement).
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19

Precautions for Correct Use

Installation and Storage Sites for FH-1000 series/FH-3000 series/FZ5-1100 series/ FZ5-600 series/FZ5-L series
Install and store the product in a location that meets the following conditions:
• Surrounding temperature of 0 to +50°C
• No rapid changes in temperature (place where dew does not form)
• Relative humidity of between 35 to 85%
• No presence of corrosive or flammable gases
• Place free of dust, salts and iron particles
• Place free of vibration and shock
• Place out of direct sunlight
• Place where it will not come into contact with water, oils or chemicals
Installation and Storage Sites for FH-L series
Install and store the product in a location that meets the following conditions:
• Surrounding temperature of 0 to +55°C (-25 to +70°C in storage)
• No rapid changes in temperature (place where dew does not form)
• Relative humidity of between 10 to 90%
• No presence of corrosive or flammable gases
• Place free of dust, salts and iron particles
• Place free of vibration and shock
• Place out of direct sunlight
• Place where it will not come into contact with water, oils or chemicals
• Place not affected by strong electro-magnetic waves
• Place not near to high-voltage, or high-power equipment
Orientation of Product
• For good heat dissipation, install the product only in the position written this manual or Instruction sheet so as not to block the ventilation holes.
Ambient Temperature
• For good heat dissipation, keep the distance written this manual or Instruction sheet.
• Do not install the product immediately above significant heat sources, such as heaters, transformers, or large-capacity resistors.
• Do not let the ambient temperature exceed an operating temperature range.
• Provide a forced-air fan cooling or air conditioning if the ambient temperature is near the upper range of operating temperature range so that the ambient temperature never exceeds the upper range of operating temperature range.
Noise Resistance
• Do not install the product in a cabinet containing high-voltage equipment.
• Do not install the Sensor Controller within 200 mm of power cables.
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Vision System FH/FZ5 Series
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Component Installation and Handling
• 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 a USB Memory/SD memory card. Refer to Using External Memory Device in the Vision System FH/FZ5 series User’s Manual (Cat. No. W365).
• Do not insert an SD memory card in the reverse orientation, at an angle, or in a twisting manner. Before removing a USB memory device or SD memory card, make sure that data is not being read or written to them. For a USB memory device, the memory device's LED flashes while data is being read or written. Make sure that the LED stops flashing before removing the memory device. For an SD memory card, the SD BUSY LED of Sensor Controller flashes while data is being read or written. Make sure that the LED stops flashing before removing the card.
• Turning OFF the Power When a message is displayed indicating that a task is in progress, do not turn OFF the power. Doing so causes the data in the memory to be corrupted, resulting in the product not operating properly upon the next start-up. When turns OFF, conform the followings proceedings have completed. and then operate again.
When saves using Sensor Controller:
Confirm the save processing is completed and next operation is possible.
When saves using communication command:
Intended command is completed. BUSY signal is turned OFF
• Setting of Power Source The power source need to be supplied from DC power source apparatus which is taken a save ultra-low voltage circuit: to protect high voltage.
Maintenance
• Turn OFF the power and ensure the safety before maintenance.
• Clean the lens with a lens-cleaning cloth or air brush.
• Lightly wipe off dirt with a soft cloth.
• Dirt on the image element must be removed using an air brush.
• Do not use thinners or benzene.
• To ensure safe access for operation and maintenance, separate the Sensor Controller as much as possible from high-voltage equipment and power machinery.
Communication with High-order Device
• After confirming that this product is started up, communicate with the high-order device. When this product has started up, an indefinite signal may be output from the high-order interface. To avoid this problem, clear the receiving buffer of your device at initial operations.
Fail-Safe Measures
• When controlling stages and robots using the measurement results from the Sensor Controller (axis movement output based on calibration and alignment measurement), always take fail-safe measures within the stage and robot systems, such as checking whether the data obtained from the measurement results is within the range of movement of the stages and robots.
• On a FH Sensor Controller side, supplementary use operations and branches of the Sensor Controller to configure a check flow such as “data should not be externally provide if the data is in a range from
-XXXXX to XXXXX” based on the stage/robots range of movement.
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Connecting the Sensor Controller and Monitor with a Switcher and Splitter
• Do not use devices that make the Sensor Controller recognize the monitor again when switching operation is performed. Re-recognition process in switching operation has an effect such as a delay in measurement time.
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Vision System FH/FZ5 Series
User’s Manual (Z365)

Regulations and Standards

All Series
Using Product Outside Japan
This regulation applies to FH/FZ5 sensor controller and peripheral devices. If you export (or provide a non-resident with) this product or a part of this product that falls under the category of goods (or technologies) specified by the Foreign Exchange and Foreign Trade Control Law as those which require permission or approval for export, you must obtain permission or approval or service transaction permission) pursuant to the law.
U.S. California Notice:
This product contains a lithium battery for which the following notice applies: Perchlorate Material - special handling may apply. See www.dtsc.ca.gov/hazardouswaste/perchlorate
Conformance to KC Standards
This regulation applies to FH/FZ5 sensor controller and peripheral devices. Observe the following precaution if you use this product in Korea.
• Class A Device (Broadcasting Communications Device for Office Use) This device obtained EMC registration for office use (Class A), and it is intended to be used in places other than homes. Sellers and/or users need to take note of this.
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23
FH-1000/FH-3000 series
Conformance to EC/EU Directives
This regulation applies to FH-1000/FH-5000 series Sensor Controller and peripheral devices. The FH-1000/FH-5000 series Sensor Controller is compliant with the standards below:
• EC Directive 2004/108/EC (Until April 19 2016) / EU Directive 2014/30/EU (After April 20 2016) EN61326-1 Electromagnetic environment: Industrial electromagnetic environment (EN/IEC 61326-1 Table 2)
• Also, the following condition is applied to the immunity test of this product.
If the level of disturbance of the video is such that characters on the monitor are readable, the test is a
pass.
• This product complies with EC/EU Directives. EMC-related performance of the OMRON devices that comply with EC/EU Directives will vary depending on the configuration, wiring, and other conditions of the equipment or control panel on which the OMRON devices are installed.
• The customer must, therefore, perform the final check to confirm that devices and the overall machine conform to EMC standards.
• If there is a need to respond to the EC / EU directive, please use by an analog RGB output.
Conformance to UL Standards
This regulation applies to FH-1000 and FH-3000 series Sensor Controller and peripheral devices. This product complies with UL Standards.
• UL508
FH-L series
Conformance to EC/EU Directives
This regulation applies to FH-L series Sensor Controller and peripheral devices. The FH-L series Sensor Controller is compliant with the standards below:
• EC Directive 2004/108/EC (Until April 19 2016) / EU Directive 2014/30/EU (After April 20 2016) EN61326-1 Electromagnetic environment: Industrial electromagnetic environment (EN/IEC 61326-1 Table 2)
• Also, the following condition is applied to the immunity test of this product.
If the level of disturbance of the video is such that characters on the monitor are readable, the test is a
pass.
• This product complies with EC/EU Directives. EMC-related performance of the OMRON devices that comply with EC/EU Directives will vary depending on the configuration, wiring, and other conditions of the equipment or control panel on which the OMRON devices are installed.
• The customer must, therefore, perform the final check to confirm that devices and the overall machine conform to EMC standards.
• If there is a need to respond to the EC / EU directive, please use by an analog RGB output.
Conformance to UL Standards
This regulation applies to FH-L series Sensor Controller and peripheral devices. This product complies with CSA Standards.
• UL 61010-2-201
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Vision System FH/FZ5 Series
User’s Manual (Z365)
FZ5/FZ5-L series
Conformance to EC/EU Directives
This regulation applies to FZ5/FZ5-L series Sensor Controller and peripheral devices. The FZ5/FZ5-L series Sensor Controller is compliant with the standards below:
• EC Directive 2004/108/EC (Until April 19 2016) / EU Directive 2014/30/EU (After April 20 2016) EN61326-1
• Electromagnetic environment: Industrial electromagnetic environment (EN/IEC 61326-1 Table 2)
• Also, the following condition is applied to the immunity test of this product.
If the level of disturbance of the video is such that characters on the monitor are readable, the test is a
pass.
• This product complies with EC/EU Directives. EMC-related performance of the OMRON devices that comply with EC/EU Directives will vary depending on the configuration, wiring, and other conditions of the equipment or control panel on which the OMRON devices are installed.
• The customer must, therefore, perform the final check to confirm that devices and the overall machine conform to EMC standards.
Conformance to CSA Standards
This regulation applies to FZ5/FZ5-L Sensor Controller and peripheral devices. This product complies with CSA Standards.
• CSA C22.2 No.61010-1
Vision System FH/FZ5 Series User’s Manual (Z365)
25
MEMO
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Vision System FH/FZ5 Series
User’s Manual (Z365)
Before Operation
This section describes the basic flow and preparations that are necessary to start operation.
Overview............................................................................. 28
Flow of Application ........................................................... 31
Windows............................................................................. 33
Checking the System Configuration................................ 44
Saving Settings before Turning OFF the Power and
Restarting........................................................................... 49
Accuracy ............................................................................ 51
Initializing the Controller .................................................. 52
1
Before Operation

Overview

Note
PLC or other external device
Image Input
Defect
Search
Measurement flow
FH/FZ5
Output Unit
Camera
Measurement trigger
The measurement flow is executed basically in order of the unit numbers.
Measurement results are output.
Measurement processing of the input image
Image input from the Camera
• Judgement result
• Measured values

Basic Mechanism for Measurements

An FH/FZ5-series Sensor Controller uses pre-built packages that contain all the processing tasks (for image input, measurement processing, displays, outputs, etc.) that are required for vision inspections. You arrange these packaged processes in order of execution of the vision inspection. An FH/FZ5-series Controller executes vision inspections according to user-created flows.
In the FH/FZ5, a flow that contains packaged processes that are arranged in order of execution of processing items and image processing is called a measurement flow. Processing items and measurement flows can have more than one setting. You can switch the setting based on the scene to inspect. (Reference: Setting Scenes (Measurement Flows) (p.53))
Concept of Measurement Processing
When the FH/FZ5 receives a measurement trigger from the PLC or other external device, the image input from a Camera, measurement processing, and output of measurement results (e.g., OK/NG judgement results) are executed in the order that those processing items are registered in the measurement flow.
• In the measurement flow, you can change the processing to execute based on the inspection results or input conditions of the vision inspection.
• You can use macro processing to execute pre-packaged processing items and functions in the FH/FZ5 to create original programs. This allows you to create original measurement processes, display processing, input and output processing, and settings dialog boxes that are custom-tailored to your application.
28
Overview
Vision System FH/FZ5 Series
User’s Manual (Z365)
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