OMRON ZFX-C10, ZFX-C15 User Guide

Cat. No. Z251-E1-01
Smart Sensor ZFX-C10/C15
Vision Sensor with built-in LCD monitor
USERS MANUAL
APPLICATION CONSIDERATIONS (Please Read)
1
User's Manual
BEFORE USE
BASIC OPERATIONS
SETTING THE MEASUREMENT CONDITIONS
FUNCTIONS USED DURING OPERA­TION
ADDITIONAL FUNCTIONS
PARALLEL INTERFACE
1
2
3
4
5
6
Smart Sensor
Vision Sensor with built-in LCD monitor ZFX-C10
APPENDICES
7
READ AND UNDERSTAND THIS DOCUMENT
Please read and understand this document before using the products. Please consult your OMRON representative if you have any questions or comments.
WARRANTY
OMRON’s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON­INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.
In no event shall responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS 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 OR REPAIR.
SUITABILITY FOR USE
THE PRODUCTS CONTAINED IN THIS DOCUMENT ARE NOT SAFETY RATED. THEY ARE NOT DESIGNED OR RATED FOR ENSURING SAFETY OF PERSONS, AND SHOULD NOT BE RELIED UPON AS A SAFETY COMPO­NENT OR PROTECTIVE DEVICE FOR SUCH PURPOSES. Please refer to separate catalogs for OMRON’s safety rated products.
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer’s application or use of the product.
At the customer’s request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product, machine, system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this document.
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ZFX-C User’s Manual
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
equipment, amusement machines, vehicles, safety equipment, and installations subject to separate industry
or government regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS 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 IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PERFORMANCE DATA
Performance data given in this document 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 users must correlate it to actual application requirements. Actual performance is subject to the OMRON 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 model 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 model numbers may be assigned to fix or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual specifications of purchased products.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.
ERRORS AND OMISSIONS
The information in this document has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user’s programming of a programmable product, or any consequence thereof.
COPYRIGHT AND COPY PERMISSION
This document shall not be copied for sales or promotions without permission.
This document is protected by copyright and is intended solely for use in conjunction with the product. Please notify us before copying or reproducing this document in any manner, for any other purpose. If copying or transmitting this document to another, please copy or transmit it in its entirety.
ZFX-C User’s Manual
3
Meanings of Signal Words
The following signal words are used in this manual.
Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or may result in serious injury or death. Additionally there may be significant property damage.
Meanings of Alert Symbols
The following alert symbols are used in this manual
Indicates general prohibitions for which there is no specific symbol.
Indicates the possibility of laser radiation.
Indicates the possibility of explosion under specific conditions.
This product is not designed or rated for ensuring safety of persons.
Do not use it for such purposes.
The camera with lighting emits visible light, which may adversely affect the eyes in rare instances.
Do not look directly into the light emitted from the Camera. When the subject is a specular
reflective object, protect your eyes from reflected light.
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.
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ZFX-C User’s Manual
Precautions for Safe Use
The following points are important to ensure safety, so make sure that they are strictly observed.
1.Installation Environment
• Do not use the product in environments where it can be exposed to inflammable/explosive gas.
• To secure the safety of operation and maintenance, do not install the product close to high-voltage devices
and power devices.
• Install the product in such a way that its ventilation holes are not blocked.
• Tighten mounting screws at the torque specified in this manual.
2.Power Supply and Wiring
• The voltage and AC power supply must be within the rated range (24 VDC ±10%).
• Reverse connection of the power supply is not allowed.
• Use the power supply within the rated load.
• High-voltage lines and power lines must be wired separately from this product. Wiring them together or
placing them in the same duct may cause induction, resulting in malfunction or damage.
• Use the product within the power supply voltage specified in this manual.
• Use a DC power supply with safety measures against high-voltage spikes (safety extra low-voltage circuits
on the secondary side).
• Tighten mounting screws at the torque specified in this manual.
3.Other
• Do not use this product in safety circuits associated with nuclear power and human life.
• Do not disassemble, repair, modify, deform by pressure, or incinerate this product.
• Dispose of this product as industrial waste.
• Connect the exclusive devices (Camera and Controller). The product might break down or malfunction if
you use a part not included in the exclusive products.
• Should you notice any abnormalities, immediately stop use, turn OFF the power supply, and contact your
OMRON representative.
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5
Precautions for Correct Use
Observe the following precautions to prevent failure to operate, malfunctions, or undesirable effects on product performance.
1.Installation Site
Do not install this product in locations subjected to the following conditions:
• Ambient temperature outside the rating
• Rapid temperature fluctuations (causing condensation)
• Relative humidity outside the range of 35 to 85%
• Direct vibration or shock
• Reflection of intense light (such as other laser beams, electric arc-welding machines, or ultra-violet light)
• Direct sunlight or near heaters
• Strong magnetic or electric field
Also, do not install this product in locations subjected to the following conditions to ensure its protective performance as described in the specifications:
• Presence of corrosive or flammable gases
• Presence of dust, salt, or iron particles
• Water, oil, or chemical fumes or spray, or mist atmospheres
2.Power Supply and Wiring
• When using a commercially available switching regulator, make sure that the FG terminal is grounded.
• If surge currents are present in the power lines, connect surge absorbers that suit the operating
environment.
• Before turning ON the power after the product is connected, make sure that the power supply voltage is
correct, there are no incorrect connections (e.g. load short-circuit) and the load current is appropriate.
Incorrect wiring may result in breakdown of the product.
• Before connecting/disconnecting cables, make sure that the product is turned OFF. The product may break
down if it is connected/disconnected while the power is ON.
• For cables, use only the exclusive products specified in this manual.
p.14, p.15
• Use only combinations of the Camera and Controller specified in this manual.
• Do not turn the power OFF in the following instances. Doing so will damage data that is in the process of
being saved.
- While data is being saved on the Controller
- While data is being saved on the SD card
• The LCD panel has been made using precision technology, and sometimes a few pixels are missing in the
panel. This is due to the structure of the LCD panel, and is not a malfunction.
• Do not remove the base from the Camera.
3.Maintenance and Inspection
Do not use thinner, benzene, acetone or kerosene to clean the Camera and Controller. If large dust particles adhere to the Camera, use a blower brush (used to clean camera lenses) to blow them off. Do not use breath from your mouth to blow the dust off. To remove dust particles from the Camera, wipe gently with a soft cloth (for cleaning lenses) moistened with a small amount of alcohol. Do not use excessive force to wipe off dust particles. Scratches to the Camera might cause error.
4.Ventilation Film
• Do not peel of the ventilation film or prod it with a sharp-pointed object. This might impair its protective structure.
• Do not cover the ventilation film. Doing so might cause the Camera's front panel to cloud.
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ZFX-C User’s Manual
5.Optional Lighting Connector
When the optional lighting is not connected, be sure to attach the connector cap. Otherwise, its protective structure might be impaired.
Editor's Note
Meaning of Symbols
Menu items that are displayed on the Controller's LCD screen, and windows, dialog boxes and other GUI elements displayed on the PC are indicated enclosed by brackets "[ ]".
Visual Aids
Important
Indicates points that are important to achieve the full product performance, such as operational precautions.
Note
Indicates application procedures.
Indicates pages where related information can be found.
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MEMO
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ZFX-C User’s Manual
CONTENTS
1.BEFORE USE
ZFX-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Part Names and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting and Connecting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installing Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installing the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Overview of Settings and Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Outline of MENU mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Measurement Items and Banks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Initializing Controller Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Saving Setup Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.BASIC OPERATIONS
Inspection Setup and Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Setting Measurement Conditions - MENU Mode . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checking the Measurement Status - ADJ Mode . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starting Measurement - RUN Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Clear Images Cannot be Obtained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Measurement Target Cannot be Measured Accurately Due to Movement . . . . . 43
To Output Measurement Values to a PC or PLC . . . . . . . . . . . . . . . . . . . . . . . . . 44
To Output Position Information of Measurement Targets as Actual Coordinates 44
CONTENTS
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3.SETTING THE MEASUREMENT CONDITIONS
Setting Measurement Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shape Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pattern Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Sensitive Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Size Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Edge Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Bright/Color Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Bright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
HUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspection by Individual Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Image Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Cameras/Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Shutter Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Gain Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Partial Function Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Image Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Light Control (Recipe Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Registering Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Position Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Additional Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Setting Reflection of Individual Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.FUNCTIONS USED DURING OPERATION
Monitoring the Measurement Status - RUN Mode . . . . . . . . . . . . . . . . . 100
Displaying Measurement Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Switching the Image Display Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Checking/Adjusting the Measurement - ADJ Mode . . . . . . . . . . . . . . . . 103
Checking Measurement Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Switching the Image Display Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Using a Saved Image to Perform Re-measurement . . . . . . . . . . . . . . . . . . . . . 105
Adjusting Measurement Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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5.ADDITIONAL FUNCTIONS
Bank Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Bank Data Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Bank Group Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Camera Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Output Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Display Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Operation Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Measurement Control Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Operation Conditions during Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Setting/Changing the Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Setting/Changing the Date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Clearing Saved Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Saving/Loading Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SD Card Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Checking Density Distribution (Profile) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Checking the Communication Status with External Devices . . . . . . . . . . . . . . . 123
Displaying the Controller Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
CONTENTS
6.PARALLEL INTERFACE
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Parallel Connector Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Internal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Signal I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Timing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Measurement (Handshaking OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Measurement (Handshaking ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Commands Other than for Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Signal Operation in terms of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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7.APPENDICES
Error Messages and Corrective Actions. . . . . . . . . . . . . . . . . . . . . . . . . 146
List of Available Functions for Each Camera . . . . . . . . . . . . . . . . . . . . . 147
AUTO Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
AUTO Setting of Measurement Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
AUTO Setting in Individual Adjustment Screens . . . . . . . . . . . . . . . . . . . . . . . . 149
Specifications and External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 150
Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Accessories & Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
LED Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Requirements from Regulations and Standards . . . . . . . . . . . . . . . . . . 168
Summary of Requirements to Manufactures . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Summary of Requirements to User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Definitions of Laser Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Basic Knowledge for Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Menu List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
How Color Images are Processed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Color Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Color Pickup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Hue, Saturation and Brightness Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
12
ZFX-C User’s Manual
BEFORE USE
ZFX-C 14
System Configuration 14
Part Names and Functions 16
Mounting and Connecting Devices 19
Installing Cameras 19
Installing the Controller 25
Connecting Devices 28
Overview of Settings and Measurement 31
Operation Modes 31
Outline of MENU mode 32
Measurement Items and Banks 33
Initializing Controller Settings 35
Saving Setup Data 36
1
BEFORE USE
ZFX-C
3 42
1
The ZFX-C is a series of vision sensors that senses objects by their “surfaces.“ Objects captured by a camera can be checked on the built-in 3.5-inch LCD monitor.
System Configuration
Basically, the ZFX-C is configured by the Controller and the camera.
Other external devices can be selected to be used in combination with the ZFX-C according to the user’s specific requirements.
Cameras with lighting
(cable built-in)
- Color camera ZFX-SC10/SC50/SC50W
ZFX-SC90/SC90W
ZFX-SC150/SC150W
- Monochrome camera ZFX-SR10/SR50
Camera only
- Color camera ZFX-SC
- Monochrome camera ZFX-S
A CCTV lens and light source will be required.
Touch pen
(*1)
Camera cable
ZFX-VS/VSR
Controller ZFX-C_
Monitor cable
FZ-VM
SD Card (*4)
RS-232C cable
ZFX-XPT2A
RS-422 cable
ZFX-XPT2B
Parallel I/O cable
ZFX-VP
LCD monitor (option)
FZ-M08 (*2)
PC
USB
Ethemet
Console ZFX-KP
PLC
(*3)
*1: The Touch Pen (ZFX-TP) is supplied with the Controller.
*2: The same image as in the Controller's LCD monitor can be displayed in the LCD monitor (option).
*3: The console can be used instead of the Controller's keys and menu buttons.
*4: Conforms to the SD Card “Physical layer specifications 1.01.”
File format: FAT16
14
ZFX-C
ZFX-C User’s Manual
Options
Extension cable for connecting cameras and the Controller
Cameras with lighting
1
BEFORE USE
Extension cable
(*1)
Extension cable
(*1,*2)
(cable built-in)
Camera only
Camera cable
ZFX-VS/VSR
2 m
5 to 18 m
3 m/8 m
8 to 19 m
ZFX-XC_A/XC_AR
3m/8m
ZFX-XC_A/XC_AR
3m/8m
*1: Up to two ZFX-XC_A/XC-AR can be connected between the camera cable and the Controller.
*2: Two ZFX-XC8A cannot be connected to each other when used with ZFX-VS (8 m.)
Optional lighting
The following optional lighting can be connected to ZFX-SC50/SC50W/SC90/SC90W.
• Bar lighting ZFV-LTL01
• Bar double-lighting ZFV-LTL02
• Bar low-angle lighting ZFV-LTL04
• Light Source for Through-beam Lighting ZFV-LTF01
ZFX-C User’s Manual
ZFX-C
15
Part Names and Functions
Cameras
Cameras with lighting
ZFX­SC10/SR10/SR50
(2)
(4)
ZFX-SC50/SC50W
(3)
(2)
(4)
(3)
(1)
ZFX-SC90/SC90W ZFX-SC150/SC150W
(2)
(4)
(3)
(1)
(3)
(4)
(2)
(2)
Camera only (C-mount type)
ZFX-S/SC
(5)
(6)
(7)
Name. Description
(1)Optional lighting connector This connector is used to connect an optional lighting. (ZFX-SC50/SC50W/
SC90/SC90W)
Important
When no optional lighting is used, make sure that the connector is covered with the cap. If not, water-resistant performance will be deteriorated.
(2)Ventilation film This film prevents the front panel from condensation.
Important
• Do not peel off or probe the ventilation film with a sharp-pointed object. If you do that the protective structure rating may no longer be satisfied.
• Do not cover the ventilation film rating. Doing so might cause the front panel to be condensed.
(3)Focus adjustment control This control is used for adjusting the focus of the image.
(4)Mounting fixture This mounting fixture is used for fastening the camera when installing it. The
mounting fixture can be installed on all of the four mounting surfaces.
(5)Lighting connector This connector is used to connect an external lighting (Strobe Controller).
(6)Camera cable connector
(7)Camera mounting base
This connector is used for connecting to the Controller via a camera cable (ZFX-VS/VSR).
This camera mounting base is fastened with screws to hold the camera in place. The camera mounting base can be installed on all of the four mounting surfaces.
16
ZFX-C
ZFX-C User’s Manual
Controller
Front
(4)
Operation panel cover
Top
Bottom
(1)
(2)
CAMERA1
CAMERA2
(1)
ETHERNET
(2) (3)
RS-232C
PARALLEL1
CONSOLE
PARALLEL0
(4) (5)
(9)
OMRON ZFX-C10
OUTPUT
RUN
(2)
1234
(3)
USB
ENABLE
ERROR
ADJ
MENU RUN
AUTO ESC
SET
PULL OPEN
SD
CARD
(5)
(6) (7)
(8)
(1)
RGB
Front
Name Function
(1) Indicator “Measuring” indicator (RUN): Lights in green when in the RUN mode.
Error indicator (ERROR): Lights in red when an error occurs. Judgment indicator (OUTPUT): Lights in orange when the judgment result is
OK or NG according to the setting. (Note)
Trigger indicator (ENABLE): Lights in blue when the ZFX-C is ready for the
measurement trigger input.
(2) LCD monitor/touch panel The LCD monitor displays setup menus and images captured from the cam-
eras. Various settings can be made on the touch panel by tapping menu but­tons in the LCD monitor using the touch pen.
(3) Function keys Specific functions are allocated to the Function keys.
(4) Touch pen The touch pen is used to operate the touch panel. This pen can be attached to
the Controller by tying its strap to the strap holder for the touch pen.
(5) USB port This port is for connecting to a personal computer via a USB cable.
(6) SD card slot This slot is for inserting the SD Card.
When the SD Card is inserted, the SD mark is displayed at the top right of the screen. Blue SD mark: The SD card is inserted but not being accessed. Red SD mark: The SD card is being accessed.
(7) Mode switch This switch selects the operation mode.
MENU: Select this mode when setting measurement conditions. ADJ: Select this mode when adjusting setting parameters as necessary refer-
encing the image and values displayed on the LCD monitor during con­tinuous test measurement (measurement without measurement data output to external devices).
RUN: Select this mode when performing measurement.
(8) Control keys These keys are used to perform operations without the use of the touch pen.
(9) Strap holder for touch pen This holder is for attaching the touch pen.
1
BEFORE USE
Note: The judgment result is output to the OR signal via the parallel interface.
ZFX-C User’s Manual
ZFX-C
17
Top
Name Function
(1) Monitor connector This connector is for connecting to the LCD monitor (option) via a monitor
cable.
(2) Camera connector This connector is for connecting to a camera.
Bottom
Name Function
(1) Ethernet port This port is for connecting to a personal computer via a 100Base-TX/10Base-T
cable.
(2) RS-232C/422 connector This connector is for connecting to a PLC via an RS-232C or an RS-422
cable.
(3) Console connector
(4) Power connector
(5)Parallel port This port is for connecting to devices such as a PLC using the parallel
This port is for connecting to the Console.
This connector is for connecting to the DC power supply.
cable. p.14
p.14
p.14
p.28
, p.126
Important
• Attach the connector caps to connectors that are not in use to prevent dust or dirt from getting inside the connectors
and to prevent the Controller from static electricity.
18
ZFX-C
ZFX-C User’s Manual
Mounting and Connecting Devices
Installing Cameras
Camera with Lighting
Optical chart
ZFX-SC10/SR10
Setting distance L (mm)
60
50
49
Setting distance (L)
Detection range (H)
ZFX-SR50 ZFX-SC50/SC50W
Setting distance L (mm)
300
194
100
34
0
5
Setting distance L (mm)
190
187
100
1
BEFORE USE
104
9
Detection range H (mm)
38
30
9
10 50
ZFX-SC90/SC90W ZFX-SC150/SC150W
Setting distance L (mm)
160
142
100
67
40
50
ZFX-C User’s Manual
Detection range H (mm)
70
Detection range H (mm)
60
10040
90
31
30
9
10
Setting distance L (mm)
240
227
180
115
100
90
Detection range H (mm)
12080
Detection range H (mm)
Mounting and Connecting Devices
50
160
150
19
Note
• The lens has a fixed focal point. The actual detection range and focal point vary from lens to lens, so adjust the
distance to the measurement target after replacing the lens or camera.
• The camera mounting distance listed in the following tables is an approximate value. Mount the Camera so that
the distance to the measurement target can be adjusted easily.
• If the object size and detection range are incompatible, use a combination of a camera (without lighting), standard
CCTV lens and light source.
Camera Only p.22
Installing the mounting fixture
The mounting fixture can be installed on all of the four mounting surfaces.
Hooks
Mounting fixture
Grooves on camera
1 Align the two hooks on one side of the mounting fix-
ture with the two grooves on the camera body.
2 Push the other hook down until it is snapped into
place.
Make sure that the mounting fixture is firmly fixed on the camera.
3 Fasten the mounting fixture at the mounting location
with screws.
Tightening torque
M4: 1.2 N•m 1/4”-20 UNC: 2.6 N•m
Removal procedure
Mounting fixture
20
Mounting and Connecting Devices
1 Insert a screwdriver into the gap (one of the two gaps) be-
tween the mounting fixture and the camera case, and re-
move the mounting fixture
.
ZFX-C User’s Manual
Adjusting the camera focus
1 Adjust the distance between the camera and the mea-
surement target and fasten the camera.
Refer to the optical chart and set the camera in a position so that the area to be checked is within the detection area (LCD monitor).
Setting distance (L)
Detection range (H)
Focus adjustment control
Note
First turn the focus adjustment control slightly to the left and right, to make sure that the Focus adjustment control is not at the upper or lower limit positions. Do not exert unnecessary force to turn the control at the upper or lower limit positions as this might damage the control. (For ZFX-SC90_/SC150_, the control stops turning at the nearest position. It turns free at the farthest position.)
2 Turn the focus adjustment control to the left and right
Optical chart p.19
to adjust the focus.
1
BEFORE USE
ZFX-C User’s Manual
Mounting and Connecting Devices
21
Camera Only
Optical chart
The values in the following chart are approximations, and the Camera must be adjusted after it is mounted.
Lens model 3Z4S-LE
ML-5018
10000
ML-3519 ML-2514
ML-1614
Camera distance A(mm)Camera distance A(mm)
1000
10000
1000
200
100
40
4 10 100 1000
Detection range(mm)
t0
t2
t0
t50
t60
t45
t50
t40 t45
t40
t35
t35
t30
t30
t25
t25
t20
t20
t15
t5
t10
t15
t2
t5
t10
2 10 100 1000
ML-1214
ML-0813
ML-0614
t: Extension tube
Example t0: Extension tube
is not required.
t5: 5-mm extension
tube is required.
Lens model 3Z4S-LE
ML-10035
ML-7527
22
Mounting and Connecting Devices
ZFX-C User’s Manual
The X axis of the optical chart shows detection range L (mm), and the Y axis shows the camera distance A (mm). The curves on the optical chart show the relationship between the detection range and camera distance for each CCTV lens. The values are significantly different for each lens, so double-check the model of the lens before using the graph. The “t” values indicate the lengths of the Extension Tubes. The value “t0” shows the case where an Extension Tube is not required and the value “t5.0” shows the case where a 5-mm Extension Tube is used.
1
Example
When a 3Z4S-LE ML-5018 CCTV Lens is being used and a detection range of 40 mm is required at the measurement target, a camera distance of 500 mm and 5-mm Extension Tube are required.
Camera
Extension Tube t_ (mm)
Lens
Camera distance A (mm)
Measurement object
Detection range L (mm)
Lenses and lens diameters
BEFORE USE
Filter thread
Total length
1-32 UNF (C-mount thread)
Lens Focal length Brightness
3Z4S-LE ML-0614 6 mm F1.4 30 mm dia. 30 mm M27 P0.5
3Z4S-LE ML-0813 8 mm F1.3 30 mm dia. 34.5 mm M25.5 P0.5
3Z4S-LE ML-1214 12 mm F1.4 30 mm dia. 34.5 mm M27 P0.5
3Z4S-LE ML-1614 16 mm F1.4 30 mm dia. 24.5 mm M27 P0.5
3Z4S-LE ML-2514 25 mm F1.4 30 mm dia. 24.5 mm M27 P0.5
3Z4S-LE ML-3519 35 mm F1.9 30 mm dia. 29 mm M27 P0.5
3Z4S-LE ML-5018 50 mm F1.8 32 mm dia. 37 mm M30.5 P0.5
3Z4S-LE ML-7527 75 mm F2.7 32 mm dia. 42.5 mm M30.5 P0.5
3Z4S-LE ML-10035 100 mm F3.5 32 mm dia. 43.9 mm M30.5 P0.5
ZFX-C User’s Manual
Max. dia.
Maximum outer diameter
Total length Filter size
Mounting and Connecting Devices
23
Extension Tubes
One or more Extension Tubes can be inserted between the lens and the Camera to focus the Camera image. Use a combination of one or more of the seven tubes to achieve the required length.
Extension Tube
Model
3Z4S-LE ML-EXR 31 dia. Set of 7 tubes
Important
• Do not use the 0.5-mm, 1.0-mm and 2.0-mm Extension Tubes attached to each other. Since these Extension Tubes
are placed over the threaded section of the Lens or other Extension Tube, the connection may loosen when more
than one 0.5-mm, 1.0-mm or 2.0-mm Extension Tube are used together.
• Reinforcement may be required for combinations of Extension Tubes exceeding 30 mm if the Camera is subject to
vibration.
Maximum outer diameter
Length
Length: 40 mm 20 mm 10 mm 5 mm 1 mm2 mm 0.5 mm
Installing the Camera Mounting Base
The camera mounting base mounted on the bottom of the camera can be installed on all of the four mounting surfaces. To change the mounting surface, remove the three mounting screws (M2 x 6) from the camera.
Camera Mounting Base
• Tightening torque when fastening the camera mounting base at the mounting location
M4: 1.2 N•m 1/4”-20 UNC: 2.6 N•m
24
Mounting and Connecting Devices
ZFX-C User’s Manual
Installing the Controller
Installation Precautions
To improve heat radiation, install the Controller only in the orientation show below.
1
Right
Do not install the Controller in the following orientations.
Wrong Wrong
Important
• Install the Controller so that the distance between the Controller and other devices is at least the dimensions shown
in the figure below to improve the ventilation.
When installing Controller only:
When installing the Controller With the Exhaust Unit attached:
Min. 15 mm
BEFORE USE
Min. 50 mm
• Keep the ambient temperature less than 50 °C. If the ambient temperature is higher than 50 °C, install a fan forced
cooling system or an air conditioner to keep the temperature lower than 50 °C.
• Avoid mounting on a panel, in which high-voltage emitting devices are installed to prevent ZFX-C operation from
being affected by noise.
• Allow at least 10 m between the Controller and power lines to keep noise at a low level in the operating environ-
ment.
ZFX-C User’s Manual
Min. 15 mm
Min. 50 mm
Mounting and Connecting Devices
25
Installing on the DIN Track
1 Hook the Controller’s upper hook onto the DIN track.
1
2 Push the Controller down onto the DIN track until its
lower hook is snapped into place.
2
Important
•Attach the End Plate (sold separately) to both sides of the
Controller on the DIN track.
•Attach the Exhaust Unit (supplied) to the Controller when
installing other devices adjacently on the same DIN track
as the Controller.
OMRON
OUTPUT
ZFX-C10
1234
RUN
p.20
End Plate (sold separately) PFP-M
USB
ENABLE
ERROR
ADJ
MENU RUN
AUTO ESC
SET
PULL OPEN
SD
CARD
Exhaust Unit
DIN track (sold separately)
PFP-100N (1 m) PFP-50N (0.5 m) PFP-100N2 (1 m)
Removing procedure
2
26
Mounting and Connecting Devices
1 Pull the Controller’s lower hook downwards.
2 Lift up the Controller from its bottom to remove it from
the DIN track.
1
ZFX-C User’s Manual
Mounting on a Panel
Panel mount adapters
1
Panel
1 Install the long Panel Mount Adapters on the four
holes on the Controller.
1
BEFORE USE
3
2
holes on the long Panel Mount Adapter.
3 Install the Controller with Mount Adapters attached
2 Install the short Panel Mount Adapters on the two
onto the panel from the front.
2
1
4 Hook the hooks of the mounting bracket onto the two
4
holes of the longer Mount Adapters and tighten the screws.
Tightening torque: 1.2 N•m.
5 Make sure that the Controller is firmly fixed on the
Mounting bracket
panel.
ZFX-C User’s Manual
Mounting and Connecting Devices
27
Connecting Devices
Connecting the Controller to the Power Supply
Use a power supply that meets the following specifications.
Item Specification
Power supply voltage Approx. 24 VDC (21.6 to 26.4 VDC)
Output current 1.0 A min.
Recommended power supply S8VS-06024 (24 VDC, 2.5 A)
Recommended electric wire size 0.14 to 1.5 mm2 (max. 1 m)
Important
Use a DC power supply with countermeasures against high voltages (safe extra low-voltage circuits on the secondary side). If the system must meet UL standards, use a UL class II power supply.
1 Loosen the two screws on the top of the Power con-
nector (male) using a flat-blade screwdriver.
2 Insert the DC power terminal (wire) into the Power
connector (male) and tighten the two screws on the top of the Power connector to fasten the power termi­nal with the screwdriver.
+
-
24 VDC
Tightening torque: 0.22 to 0.25 N•m.
3 Plug the Power connector (male) into the Controller’s
Power connector (female).
4
Tighten the two screws on the left and right of the Power
connector (male) with the screwdriver to fasten it.
Tightening torque: 0.22 to 0.25 N•m.
Attaching Ferrite Cores
Attach ferrite cores (supplied) to both ends of the camera's cable and the Controller's power cable, respectively.
Ferrite coreFerrite core
Ferrte core
When attaching ferrite cores to the Controller's power cable, pass the cable once through each ferrite core.
-
+
DC power supply
28
Mounting and Connecting Devices
ZFX-C User’s Manual
Connecting the Camera to the Controller
1Insert the camera’s connector into the Controller’s
Camera connector.
Make sure that you hear the connector snap firmly into place when it is connected.
2Tighten the two fastening screws of the Controller’s
Camera connector.
Tightening torque: 0.15 N•m.
Important
•Do not touch the terminals inside the connector.
•Fasten the connector while making sure that it is not subjected
to vibration or shock.
•Do not mount the Controller in such a way that a load is steadily
applied on the connector, for example, with tension applied to
the cables.
To extend the installation distance between cameras and the Controller, see p.15
1
BEFORE USE
Disconnection procedure
Loosen the fastening screws (two locations) to unlock the camera’s cable, and then pull the camera’s cable connector straight out.
Important
• Be sure to hold the connector of the camera to disconnect it. Failure to do so may damage the camera’s cable.
• Do not touch the terminals inside the connector.
ZFX-C User’s Manual
Mounting and Connecting Devices
29
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